Material/Chemical Handling

Milad Nadereh Abbasi 8557045Amir Shadmehri 8557029Fazel Moradi 8557041Ali Soleymani 8557028Komeil Zamani 8557026

Professor :Ph.D. Setareh

In the name of ALLAH

We want to consider the nature and mitigation of the hazards

associated with the movement and handling of materials.

Then we consider standard methods for classifying material

hazards.

Since safe handling requires knowledge of associated hazards

these are dealt with next.

The discussion then turns to the specifics of handling

materials, in the sequence liquids, solids ,gases and wastes.

In this discussion, the term "material" refers to both

chemical and nonchemical substances.

Chemicals are those substances with readily definable

compositions, such as calcium chloride, sulfuric acid, vinyl

acetate, and methyl isocyanine.

Nonchemical are those substances whose chemical

structures are not readily defined, such as wood, hydraulic

oils, cereal grains and ceramics.

The safe handling of a given material in any situation

requires consideration of two factors:

• intrinsically hazardous properties of the material.

• hazardous conditions created during storage,

transport, and processing.

These properties can be found in the Material Safety

Data Sheets (MSDS-1-2).

HAZARDOUS PROPERTY IDENTIFICATION

The process of identifying material hazards in

the plant should include the following:

list of all materials received, stored, used, or

manufactured on site

• raw materials

• Intermediates

• finished products

• maintenance materials

MSDS for all materials in the above list.

all storage vessels affixed with the appropriate NFPA

Diamond consistent with the 704M system.

DOT shipping label on all materials shipped or

dispatched. Typical DOT labels are shown in following

Figure:

An Standard 704 for the identification of hazards. The

symbol used is a diamond divided into its four corners. Each

of the corners represents a different type of hazard. Health,

fire, and reactivity hazards are quantified to a degree by a

numeral in the appropriate field.

These labels allow recognition of hazards at a glance and

are widely used on containers, storage tanks, items of

operating equipment, and certain area of buildings.

The following figure explains NFPA's 704M Diamond

System.

The name of the material or one of the following

identification numbers should be placed on or under the

diamond:

• Chemical Abstracts Service (CAS) registry number

• NIOSH Registry of Toxic Effects of Chemical

Substances (RTECS) number

• Department of Transportation identification (DOT ID)

number

Identification numbers for some hazardous substances are

in the following Table.

Material Identification Numbers

DOT ID Number

NIOSH RTCS Number

CAS Registry Number

Material

1093 AT5250000 107-13-1 Acrylonitrile

1114 CY1400000 71-43-2 Benzene

1402 EV9400000 75-20-7 Calcium Carbid

1072 or 1073 RS2060000 7782-44-7 Oxygen

1338,1381 or 2447

TH3500000 7723-14-0 Phosphorus

Toxic substances are regulated under CFR Title 40.

Before a substance can be manufactured, it must be properly

registered with the EPA in accordance with the Toxic Substance

Control Act (TSCA).

In the case of a new substance not on the TSCA inventory, a

pre manufacturing notice (PMN) must be submitted to

the EPA. This notice must contain information on:• identity• use• anticipated production volume• hazards• disposal characteristics of the substance.

It is the seller's responsibility to see that TSCA

requirements are met and that any changes in process,

formulation, etc.

That change the conditions of registry are reported.

The seller is also obliged to include an MSDS with each

shipment.

The importer of a new substance has the same

responsibilities under TSCA.

It is wise to consult a number of sources of hazard

information and to include the results in training programs

with feedback.

Surveys show that workers typically understand about

two-thirds of the information on an MSDS, and OSHA

claims that 90% of MSDS do not contain accurate

information in all required categories.

Fire & explosion:Fire (relatively slow) & explosion (rapid) phenomenon

for forming a fire three items must be considered.

1-oxygeon

2-fuel

3- Source of ignition

Remove any one item from the tried then combustion can not result.

Degree of flammability is indicated by materials explosive or flammable limits. Oxygen & some kind of materials such as (ethylene oxide) contain internal oxygen with increases sensitivity & can take part in the combustion reaction.

The source of ignition can be an open flame or a spark or a hot surface. Another factor for flaming material is interring reaction between materials improperly brought to gather.

The ways for reduction of flammability potential of flammable mixtures:

1-reduction of oxygen concentration by purring with inert gases.

2- Installing flame arresters or other insulation devices by changing in (A-vapor volume concentration. B-systems pressure)

The concentration of oxidizing agent in the mixture may increases by (A-leakage into the system by poorly joints-accidental addition by operator errors.

Electrical installation should always be in accordance with NEC & NEMA standard Codes. Other sources include:› Flares› furnaces› Engines› motor vehicles› welding & other hot works› static electricity accumulation

But in main categories of electrical hazards we have 4 stages:1-hazard related to the electrical equipments & wiring

2-hazard related to the static electricity

3-hazard related to the lightening

4-hazard related to stray current

Grounding of equipment & wiring:

The grounding of equipments & wiring of them depends on:

1-surface condition of the grounded element

2-installation of the grounding & bonding element

3-nature of soil

4-material & size of the conductor & electrodes

So: Grounded elements: surface condition, contact area,

contact pressure & etc… Grounding or bonding connects: proper type for

application, proper installation quality of work man ship.

Grounding or bonding conductors: type of conductor materials, cross sectional area, mechanical protections

Soil: Types of soil, moisture content, depth of frost line. The best way for ensuring that a grounding system will

perform properly is first to install it correctly & then test or visually inspects, test, and maintain it periodically.

Static electricity: Static electricity is generated by the friction &

separation of two dissimilar non conducting materials. Positive charge accumulates on one material &

negative charge on the other. In order to find the sources of static electricity that

may causes fire & explosion we may consider several conditions:

1-a source of static electricity generation

2-accumulation of electric charges

3-the presence of an ignition or ignitable mixtures

4-a spark discharge of sufficient energy

Method of reducing the hazards of static electricity:• 1 Grounding & bonding• 2 maintaining high atmospheric humidity• 3 increasing the conductivity of air ionization• 4 uses of non metallic shields or guards to prevent

contact of personnel with metal parts

Below methods will be reducing the number of the human errors:• 1 proper design• 2 maintenance• 3 operators training• 4 uses of barriers & visible warnings

Biological hazards:

The production of pharmaceuticals, the manufacture of enzymes or genetically engineered materials & the cultivation of biological materials can be exposed personnel to biological produced toxic agents.

DHHS has a method for establishing bio safety levels & published general operating guides.

Radiation hazard: Many process & inspections procedures depend on

radiation emitting substances & equipments potential sources of exposure includes:

1-smoke detectors using alpha emitting radioisotopes

2- radio graphical experiments & examinations

3- micro waves There are some general guide lines for handling

sources of radiation safety are:1- provides adequate labeling on radioactive materials.

2- prepare & implement employee emergency plants & fire preventing

So in accident case:

1-identify the nature of hazard

2- identify the limits of the area affected by accident

When the radiation equipments uses Make a sure that:

1-the equipment is operable

2- adequate operating & handling instructions provided

3- trained & qualified personnel are available to operate & maintain the equipment.

Thermal Hazards:

Some hazards arise when process temperatures are significantly different from ambient. The frequency of these injuries can be reduced by:

Promoting awareness of the hazard• Training• safety meetings• signposting

mitigating the hazard• enclosure of the hot or cold equipment• insulation• restriction of access to the vicinity of the hazard

protecting the worker from the hazard.• use of safety gear• availability and prompt use of simple first aid.

The working environment may also be too hot, humid, or cold for comfort.

Physical Plant Hazards:

Some safety hazards associated with material handling are the direct result of the physical work itself or the layout of the plant, such as:

 • unattended or improperly shored excavations• piping hung too low or across access ways• poorly designed or installed stairways and landings• poorly supported working surfaces and flooring• steep grades• slippery surfaces• sharp objects• poor lighting• inadequate means of egress from a hazardous area

LIQUID HANDLING

Safe handling of liquids requires identification of their hazardous properties, chiefly toxicity corrosiveness flammability Reactivity

This information will be on the MSDS, along with precautions for safe handling and use. A hazardous liquid shipped to the plant should have the appropriate DOT label, together with an ID number and associated safety documentation. While on site, the hazardous liquid must be transported and stored according to the appropriate codes and standards.

An example of this codes and standards is NFPA30 which we explain it briefly:

NFPA 30 addresses the hazards of handling and storing these liquids. This table shows the NFPA 30 classification by properties of a liquid.

The Dow Fire and Explosion Index can also be used to characterize the degree of hazard. This index combines material and process factors to assess the magnitude of a hazard and the likely extent of damage by an accident. Starting from a material factor (MF), this method derives an index by applying general (F1) and special (F2) process hazards factors.

MF reflects the hazardous nature of the material, its quantity, and the conditions of storage.

The general process hazards factor, F1, covers such considerations as the degree of enclosure of the material, the difficulty of access, and the nature of any chemical reaction.

The special process hazards factor, F2, deals with such things as toxicity of the material, temperature and pressure of storage, the possibility of leakage, and the possibility of being within the flammable region.

The calculation form in next Figure will make clear the way in which the process hazards factors are derived. The fire and explosion index results from multiplication of the factors MF, F1, and F2.

The Material Factor (MF) is the basic starting value in the computation of the F&EI and other risk analysis.

Loss Control Credit FactorsIn the construction of any chemical Process Unit (plant) consideration must

be given to a number of basic design features including compliance with various codes such as building codes or the codes of ASME, NFPA, ASTM, ANSI and requirements of local governments.

In addition to these basic design requirements, certain loss control features based on experience have proven beneficial both in preventing serious incidents and in reducing the probability and magnitude of a particular incident.

There are three categories of loss control features: C1 Process Control C2 Material Isolation C3 Fire Protection

Loss Control features should be selected for the contribution they will actually make to reducing or controlling the unit hazards being evaluated. Selecting credit features to accumulate credits is not the intent of the Risk Analysis approach; the intent is to reduce the dollars at risk or the base MPPD to a more probable, realistic value.

1. Process Control Credit Factor (C1)a. Emergency Power - 0.98

This credit is given for the provision of emergency power for essential services (instrument air, control instrumentation, agitators, pumps, etc.) with automatic changeover from normal to emergency. The emergency power credit should be taken only if it is relevant to the control of an incident in the specific Process Unit being evaluated a credit factor of 0.98 is to be given if applicable or else a factor of 1.00 is to be used which indicates no credit.

b. Cooling - 0.97 to 0.99

c. Explosion Control - 0.84 to 0.98

d. Emergency Shutdown - 0.96 to 0.99

e. Computer Control - 0.93 to 0.99

f. Inert Gas - 0.94 to 0.96

g. Operating Instructions/Procedures - 0.91 to 0.99

Adequate written operating instructions and/or a fully documented operating discipline are an important part of maintaining satisfactory control of a unit. The following conditions, listed with point ratings, are considered to be the most important:

1. Startup - 0.5

2. Routine shutdown - 0.5

3. Normal operating conditions - 0.5

4. Turndown operating conditions - 0.5

5. Standby running conditions (unit running on total recycle or reflux) - 0.5

6. Up rated operating conditions (above flow sheet capacity) - 1.0

7. Restarting shortly after a shutdown - 1.0

8. Restarting plant from a post-maintenance condition - 1.0

9. Maintenance procedures (work permits, decontamination, lockout, system clearance) - 1.5

10. Emergency shutdown - 1.5

1 1. Manufacturing unit equipment piping modifications and additions - 2.0

12. Foreseeable abnormal fault situations - 3.0

To obtain a credit factor, add all the points for the conditions that have operating instructions. The total points are represented by "X" in the following formula: 1-(x/150)

If all conditions have been covered, the credit factor will be: 1-(13.5/150)=0.91

h. Reactive Chemical Review - 0.91 to 0.98

I. Other Process Hazard Analysis - 0.91 to 0.98

2. Material Isolation Credit Factor (C2)

a. Remote Control Valves - 0.96 to 0.98

If the unit is provided with remotely operated isolation valves so that storage tanks, process vessels or major sections of transfer lines can be quickly isolated in an emergency, use a credit factor of 0.98. If such valves are cycled at least annually, use a credit factor of 0.96.

b. Dump/blowdown-0.96-0.98

c. Drainage - 0.91 to 0.97

d. Interlock - 0.98

3. Fire Protection Credit Factor (C3)

a. Leak Detection - 0.94 to 0.98

If gas detectors have been installed that alarm only and identify a zone in the plant area, use a credit factor of 0.98. When a gas detector both alarms and activates a protective system before the lower flammability limit is reached, use a credit factor of 0.94.

b. Structural Steel - 0.95 to 0.98

c. Fire Water supply - 0.94 to 0.97

d. Special Systems - 0.91

e. Sprinkler Systems - 0.74 to 0.97

f. Water Curtains - 0.97 to 0.98

g. Foam - 0.92 to 0.97

h. Hand Extinguishers Monitors - 0.93 to 0.98

i . Cable Protection - 0.94 to 0.98

The product of C1 x C2 x C3 constitutes the Loss Control Credit Factor for the Process Unit

For more information click here

Liquid Transport Hazardous liquids are transported by a variety of methods, the choice

depending on the properties of the liquid and the volume transported. Shipping containers are regulated by the DOT

Container Transport Small quantities of hazardous liquids transported on site can remain in

their DOT-approved portable containers or can be transferred to safety cans (next Figure) or portable tanks.

Rules for the use of safety cans and portable tanks for flammable liquids are in NFPA 30; many of the criteria used for aboveground permanent storage vessels apply.

Generally, the quantity of hazardous liquids transferred by these containers to their point of use should be kept to a minimum.

When transporting or using small containers: Use proper transport equipment.

• specially designed drum transport and tilting carts• special drum pallets for transport by forklift and for

stacking in racks• carboy trucks

Use proper tools to open and close containers. Connect grounding cables to containers before attempting to

transfer flammable liquids (next figure) Perform transfers in a restricted area where accidental spills

can be safely contained and then cleaned up.

Pipeline TransportWhen transferring hazardous liquids from tank cars, trucks, or

barges, or when handling large quantities of liquid during normal operation, a specially designed piping system should be installed. The most hazardous liquid handling operation is transfer from shipping container to storage.

The liquid transfer system should be designed to contain the liquid when properly assembled

and operated be constructed of materials compatible with the liquid withstand maximum operating temperatures and pressures contain easily handled leak proof connectors

contain the necessary safety devices• relief valves

• check valves or backflow preventers

• flame arresters• grounding cables• heat tracing

• Jacketing

• vapor return lines

• ventilated enclosure

Personnel training is also important to prevent accidents. To assure safe operation and the correct responses to emergencies, the following are necessary:

All involved personnel are familiar with official plant procedures and with safety information provided by the supplier of the hazardous liquid.

All vents and drains are closed prior to transfer. All isolation valves in the transfer line are open; filters and strainers

are not plugged. All grounding cables are in place on transfer lines subject to static

electricity buildup. A responsible person monitors for leaks during the transfer process. Lines are vented, drained, and cleaned as necessary after transfer is

complete. Correct personal protective equipment (PPE) is available and in

proper working order.

Liquid Storage

Hazardous liquids must be stored safely away from process and public areas and in such a manner that leaks or spills can be contained.

Good separation criteria can be incorporated into the layout of a processing facility but are not easy to implement for a laboratory or packaging operation that handles a variety of hazardous liquids.

The operator must then balance hazardous liquid accessibility against ease of operation and maintenance and should therefore:

establish proper conditions for storage • minimize the quantity of liquid stored• optimize distance between storage location and point

of use• follow all codes and standards that apply to handling

and storage of the liquid• verify that materials of construction of storage vessels

are compatible with the liquid• establish requirements to maintain contents of the

storage vessel in a safe state heating cooling inerting venting atmospheric or to recovery/destruction draining

provide appropriate devices for maintaining safe conditions pressure sensors/alarms

temperature sensors/alarms

level sensors/alarms

dip legs/tube

rupture disks

vacuum breakers conservation vents flame arresters detonation arresters sample connections vortex breakers diaphragms floating roofs double containment diking or spill diversion

determine whether the storage vessel requires special enclosure or ventilation for• protection from the environment• protection of personnel and the environment from the

vessel contents provide instrumentation to warn operators of high

liquid level in hazardous situations, provide interlocks to stop

filling or divert flow from the tank

Large Storage Tanks Volumes of hazardous materials stored on a site

should be kept to a minimum. incompatible materials should be kept separate. The practical minimum storage volume will

depend on process demands, the size of the standard shipping container, and the logistics of delivery.

Large storage vessels often are needed, and these have their own safety criteria.

Standard vessel geometry depends primarily on the volatility of the liquid:

Most leaks from tanks result from overfilling or vandalism, not from faults in design or construction.

Certain tanks will require some type of secondary containment (40 CFR 112).

The use of integral, attached steel dikes is becoming more common, and the Steel Tank Institute is developing construction standards.

Many tanks require emission controls, and some require emergency pressure relief.

These should be in accord with the API code relevant to the tank design and with NFPA 30 and 29 CFR 1910.106.

The NFPA also regulates spacing of tanks. Finally, the use of inertion to prevent explosions will make

an installation safer and will allow closer grouping of tanks. This is covered in NFPA 69.

Small Volume Storage/Area Layout Small volumes (less than 100 gallons) of hazardous

liquid required for laboratory or maintenance facilities should be stored in rooms or small buildings isolated from but close to their point of use.

Such liquids should be stored in containers that comply with regulations governing their safe handling.

For example, volatile liquids should be stored in safety cans.

Groups of safety cans containing various hazardous liquids should be stored in metal cabinets similar to that shown in Figure.

Underground Storage Tanks Underground storage tanks (USTs) are not

recommended for new installations. New installations intended to hold hazardous

materials must have high integrity and conform to Section 4003(g) of RCRA.

Where USTs already exist, they require proper safeguards.

These may include :• double wall to contain leaks • containment by surrounding membrane or concrete

structure • monitoring for leaks diversion and collection of leakage

for proper disposal• accurate records of tank inventory• insurance to cover the cost of cleanup after tank failure

Inerting Reducing the oxygen concentration below that which

supports combustion will reduce the hazard of flammable liquid storage.

Therefore some method of inerting the vapor space with a suitable gas often should be provided.

Carbon dioxide and nitrogen are the common choices. Inert gases such a helium and argon are used in special cases but are expensive.

Steam is occasionally used for liquids stored above 1700F but presents thermal hazards.

Its use can lead to generation of vapor or to the formation of vacuum as the apparatus cools. Inert gases always present the hazard of asphyxiation.

Spill Control and Cleanup Spills and leaks can occur during the normal liquid transfer

process. Transfer should then stop immediately and resume only after

the leak is eliminated and the spill cleaned up. Typical sources of leaks and spills are:

• piping flanges• hose connections• valve packing• pump packing and mechanical seals

When hazardous materials are handled, these sources of leaks should be located in curbed or diked areas to localize spills.

If a permanent curb or drain can not be provided around the leak source, a temporary curb should be provided, using barriers or absorbent materials.

Small Container Leaks Small containers leaking hazardous liquids should be

emptied immediately. The contents should be drained by gravity, siphon, or

portable pump into a more suitable container. If immediate transfer is unnecessary or impractical,

the container can be placed in another receptacle. The leaky container can then be taken to an area

where liquid transfer and cleanup can be performed safely.

Secondary Containment Units, (a) Secondary containment pallet used to transport leaking drums, (b) Single drum secondary containment

The end

Thanks for your

attention