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Title:Chemical Hazard Management ProcedureReference No. SHE-TSOH-04-1358Rev. : 0

Chemical Hazard Management Procedure

Table of Contents

1.0 Objective2.0 Scope3.0 References4.0 Responsibilities5.0 Definitions6.0 Legal Requirments7.0 Guidelines Common to all Chemicals8.0 Working with Chemicals with Specific Hazards9.0 Hazard Communication10.0 Training11.0 Exposure Assessment and Medical Surveillance12.0 Standard Operating Procedures13.0 Documentation Control14.0 Audit Requirements15.0 Renewal Process16.0 Deviation Process

Attachment A: Chemical Purchase hazard information FormAttachment B: Hazmat LabelsAttachment C: Incompatible Chemicals


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1.0 Objecti ve

The objective of Chemical Hazard Management Procedure is to provide general guidelinesfor hazardous materials:

1. Specification, ordering, purchase, handling, storage, use, transportation, emergenciesand disposal;

2. Control of hazards; and3. Hazard communication.

2.0 Scope

2.1 Scope

This procedure establishes minimum requirements for all activities under effective control ofKNPC.

2.2 Exclusions

This document does not apply to chemicals enclosed in pipelines and bulk storage facilities,hydrocarbon transport vehicles, management and control of asbestos, gaseous substancesemitted from stacks, fumes and mists and prescription medicine or drugs.

3.0 References

1. Environmental Requirements for the State of Kuwait, Environment Public Authority,2. Ministry of Oil, Kuwait, Environmental Requirements,3. Corporate Health Safety and Environment Standard 12, 19, 39, 40, 47, Kuwait

Petroleum Corporation,4. OSHA PSM for Highly Hazardous Chemicals 29 CFR 1910.1195. NFPA-30 Flammable & Combustible Liquids Code

6. Shell reference doucment on safe handling of chemicals

4.0 Responsibilities

Superintendent, Technical Support, Safety, Health & Environment is designated as competentperson to administer and maintain the elements of this document.

Line management in all KNPC departments has the responsibility to ensure implementation ofguidelines relevent to them.

Responsibility for keeping this document updated and providing overall direction and adviceon the issue shall be with Manager, Safety, Health & Environment.

Each individual (including contractor personnel) in KNPC is responsible for various provisionsof this plan as relevant to his/her job.

Users shall be aware of labeling system and shall understand information on MSDS. Theyshall follow safety instructions displayed in labels and MSDS, or as instructed.

User division superintendent shall ensure all users are aware of nature, uses and hazards ofthe material. Users shall be properly trained on general handling of hazardous material andspecial training on highly hazardous materials applicable for a particular user.

User division superintendent shall ensure the provision of required PPE and user compliance.PPE signs shall be displayed at locations wherever hazardous materials are handled orstored (e.g. eye goggles, gloves, and respiratory protection signs).

Users shall check all empty containers, equipment and tools prior to use for the condition,cleanliness, and compatibility with the material.Suppliers, warehouse personnel, transporters


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and end users shall make sure that all hazardous material containers are properly labeledand identified.

5.0 Definitions

Auto Ignit ion Temperature (AIT/IT): Minimum temperature required to initiate self-sustainedcombustion of a solid, liquid or gas in the absence of a source of ignition.

Carcinogen: A substance capable of producing cancer, mutations of genes resulting inirregular, uncontrollable growth of abnormal cells in humans.

Hazardous Chemicals (Chemicals): Elements or compounds or mixtures which arecategorised for transportation and handling as follows:

a. Physico - chemical Hazards: Explosive, oxidising and flammableb. Health Effects: Toxic, corrosive, irritant, sensitising, carcinogenic, mutagenic, toxic for

reproduction and dangerous for the environment.c. Environmental Hazard: Substances with the potential to cause harm to the

environment.The above definations includes similar terms such as hazardous materials, hazardoussubstances and highly hazardous materials.

Combustible Liquid: A liquid having a closed-cup flash point at or above 1000F (37.800C)(eg. Diesel, Fuel oil)

Combustible Liquid Flash Point 1000F (37.80C) & above

Class II 100-140 0F (37.8-600C)

Class III A 140-200 0F (60-93.30C)

Class III B 200 0F (93.30C) & above

Compressed Gases:Gases having an absolute pressure in the container exceeding 40psi(2.72 Kg/cm2) at 70oF(21.1oC), or having an absolute pressure exceeding 104psi(7.07Kg./cm2) at 130oF(54oC).

Corrosive Material:Corrosive materials are liquids, gases or solids that can destroy humanskin tissue, severely corrodes steel or other materials.

Explosives: Explosives are chemical compounds, mixture, or device whose primary purposeis to function by explosion with substantial releases of heat and gas (eg. Dynamite).

Flammable Gases:Flammable gases have flash point below room temperature and will formexplosive mixture with air or oxygen within the lower & upper explosive limits (e.g. hydrogen,light hydrocarbons like propane & acetylene).

Flammable Liquid: A liquid having a closed-cup flash point below 100 0F (37.80C) andhaving a Reid Vapor Pressure (RVP) not exceeding 40 psia (2068.6 mm Hg) at 100oF

(37.80C). (eg. Naphtha, Gasoline)

Flammable Liquid Flash Point Below 1000F (37.80C) Boiling Point

Class I A Below 730F (22.80C) below 100 0F

Class I B Below 730F (22.80C) at or above 100 0F

Class I C 73-100 0F (22.8-37.80C) n/a

Flammable Solids:A Flammable solid is any solid material other than an explosive which isliable to cause fire through friction or retained heat from manufacturing or processing or thatcan be ignited readily and when ignited, burns so vigorously and persistently as to create aserious hazard.

Flash Point (FP):Minimum temperature at which a flammable mixture of gas or vapor in air

will momentarily flash when a source of ignition (spark) is introduced.


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Immediately Dangerous to Life and Health (IDLH):Minimum concentration of contaminantin air which is IDLH.

Irritating Material:A liquid or solid, which upon contact with fire or exposure to air, gives offdangerous or intensely irritating fumes.

Lethal Concentration (LC):Toxic concentration in air which cause death of test animals.Toxicity of a substance entering the body by ingestion or absorption is measured in Toxic andLethal Doses (i.e. TD & LD for liquids, etc).

Lethal Dose (LD):Dose which killed test animals (ex. LD50 = dose or the amount that killed50% of test animals)

Lower Explosive/Flammable Limit (LEL/LFL): Minimum concentration of vapor or gas inair which will burn when a source of ignition (spark) is introduced.

Material Safety Data Sheets (MSDS):An organised basic hazard information on individualchemicals for risk appraisal and instruction of personnel in an internationally agreed onformat. 16 sections are defined for the listing of properties of products and other materialincluding toxicological, ecological, physical, flammability and regulatory requirements andemergency and disposal measures.

Mutagen: A substance capable of inducing genetic change which when transmitted to anoffspring can result in heritable variation.

Oxidizers: Oxidizers are materials that contain large amounts of chemically bound oxygenthat is easily released, especially when heated, and that will stimulate the burning ofcombustible material.

Personal Protective Equipment (PPE):Means all equipment and clothing which is intendedto be worn or held by a person at work and which affords protection against one or more risks

to health or safety. Protective includes, coverall, chemical suit, gloves, safety boot, safetyspectacles, safety helmets, safety harnesses, respirators, life jackets etc.

Poison A:A gas or vapour of a liquid of such a nature that a very small amount mixed in airis dangerous to life. (e.g. hydrogen cyanide, phosgene, nitrogen tetroxide).

Poison B: Any substance (liquid, solid, paste or semi solid) known to be so toxic that asevere health hazard exists. (E.g. TEL/TML, parathion. Aniline).

Preparation:Means mixtures or solutions of two or more chemicals.

Radioactive Materials:Any material, or combinations of materials, that spontaneously emitionizing radiation, and have a specific activity greater than 0.002 microcuries per gram.

Reprotoxic Substances: Capable of producing irregularities in the reproductive system ofeither gender, the growth of a foetus (teratogenic) and chils. This includes the lactic period.

Sensitisers:Substances which can induce changes in the respiratory system or on the skin.Once these changes have taken place, further exposure to the substance, sometimes to verysmall quantities causes the symptoms to return. Some persons are more susceptible tosensitisers than others.

Substance: Any natural or artificial substance whether in solid, liquid or gaseous form or inthe form of a gas or vapour including microorganisms.

Substance Hazardous to Health:Any substance or preparation which are:

a. Listed or must be classified according to the conventional method as very toxic, toxic,harmful, corrosive or irritant and required to display hazard warning symbols;b. Present in excess of an assigned exposure limit;


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c. A biological agent;d. Dust of any kind in substantial quantity;e. Not a substance mentioned above but which creates a hazard to the health of

members of the work force, which is comparable with the hazards created bysubstances above.

Threshold Limit Value (TLV):Atmospheric concentration of a contaminant to which, mostworkers may be exposed.

TLV-Time Weighted Average (TWA): concentration of the contaminant in air over thenormal work shift of 8 hours, to which workers can be exposed without respiratory protectionin a 40-hour workweek.

TLV-Short Term Exposure Limit (STEL): When exposed only for a short period of 15minutes. This maximum concentration can be allowed to breathe 4 times during 8 hours withminimum 1-hour interval between exposures.

Toxicity: Toxicity of a material entering the body by inhalation is measured in Toxic andLethal Concentrations (i.e. TC & LC for gases, vapor or dust).

Toxic Concentration (TC):Minimum toxic concentration in air which cause toxic effect.

Toxic Dose (TD):Minimum dose to cause toxic effects

Upper Explosive/Flammable Limit (UEL/UFL): Maximum vapor/gas to air concentrationabove which flame propagation will not occur, i.e. the mixture is too rich to burn.

User: User shall mean the personnel involved in using, handling, storing, transporting andemergency response of hazardous materials.

6.0 Legal Requirements

6.1 National and International Protocols

The chemical control policies KNPC shall be in harmony with Kuwait EPA requirements (inperticular chapter III, October 2002) and any applicable national and international legislationand protocols to which the State of Kuwait has subscribed.

7.0 Guidelines Common to Chemicals

7.1 Purchase Control and Approval for New Chemicals and NewChemical Use

7.1.1 It shall be the responsibility of the person specifying or ordering any hazardouschemical to ascertain if the chemical is really required or if its use can be eliminatedby changing the process or its design. If the substance cannot be eliminated,possibility of substituting by safer alternative shall be looked into.

7.1.2 The hazards to health and to environment associated with chemicals shall beascertained before delivery to sites is undertaken. It is important to note that differentforms of the same substance may present different hazards.

Identification of the hazards of chemicals is the basis for a risk assessment to beundertaken. The findings of the risk assessment will enable the person handling thechemicals to take the necessary measures to protect his health, safety and also toprotect the environment.Such records shall be maintained in the form of Occupational

Health Risk Register.


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7.1.3 It shall be the resposibility of the indenter of any chemical to complete ChemicalPurchase Hazard Information Form (Appendix A). The form shall be submitted to theSuperintendent, Technical Support, Safety, Health and Environment.

7.1.4 It shall be the responsibility of Purchase Division to specifically mention requirmentfor MSDS in the KNPC approved format as a mandatory part of any purchase of anyhazardous material. MSDS submitted by the supplier shall be approved by thecompetent person before transportion of the material to KNPC sites.

7.1.5 The driver of any transport bringing hazardous chemicals to KNPC sites, will carry inperson appproved MSDS. No gate pass shall be issued to KNPC sites withoutattaching a copy of approved MSDS. This will be the resposibility of the gate passissuing authority.

Contractor bringing any chemicals must submit Chemical Purchase HazardInformation Form to Superintendent, Technical Support, Safety, Health andEnvironment through his sponsor superitendent and obtain necessary approval.

7.2 General Precautions

7.2.1 Hazardous materials should be handled in closed systems wherever possible.7.2.2 Safety Shower/eyewash shall be available near the chemical handling area. It shall

be painted in green & white and provided with green & white identification symbolvisible from distance.

7.2.3 Plant chemical shelters should be away from hazardous area. Overstocking ofchemicals shall be avoided in unit chemical shelters.

7.2.4 Expired material shall be disposed in compliance with KNPC and Kuwait Govt.environmental regulations.

7.2.5 Waste material (including radioactive waste) shall be disposed in accordance with theKNPC Environmental Regulations.

7.3 Guidelines for Storage of Chemicals

7.3.1 The consequences of unplanned storage of chemicals can bedisastrous for example it can initiate an explosion or the release of toxic fumes intothe atmosphere should dissimilar chemicals come into contact with one another.Substances of different hazard classifications must not be stored together.

7.3.2 The following are general guidelines for storage of chemicals:a. Ensure that all containers are in good condition and properly labeled.b. Store incompatible chemicals separately.c. Segregate chemicals by hazard class (flammable liquids, oxidizers, etc.).d. Ensure that storage locations are dry and adequately ventilated.e. Flammables shall not be stored with any other types of hazardous substances.

f. Store highly reactive or corrosive liquids in spill trays.g. Toxic substances shall not be stored with any other substance.

7.3.3 Separate storage areas shall be provided for incompatible chemicals as thesechemicals may react together and create a hazardous condition because of thisreaction (See Appendix- C).

7.4 Guidelines for Safe Use of Chemicals

7.4.1 Knowledge of hazards associated with the materials7.4.2 Review of emergency procedures and ensure that necessary supplies and equipment

for emergency response are available.7.4.3 Know the locations of safety equipment such as emergency shower, eyewash, fire

extinguisher, fire alarm and emergency phone numbers.7.4.4 Wear appropriate personal protective equipment and take proper care for using them.


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7.4.5 Wear appropriate respiratory equipment when air contaminant concentrations cannotbe sufficiently restricted by engineering controls.

7.4.6 Keep work areas clean and uncluttered with chemicals and equipment properlylabeled and stored.

7.4.7 Always wash hands and other exposed skin after chemical use.

7.5 Tansportation and Handling within Work Site

7.5.1 Driver and other person transporting and handling chemicals shall be trained onhandling chemicals and emergency response. Before transportation responsiblepersonnel shall ensure labels on the container are intact and proper personalprotective equipment are used. Copy of MSDS shall be carried during transportation.Incase of emergeny ECCC shall be contacted in telephone number 888.

7.6 Empty chemical containers:

7.6.1 A container is empty (according to U.S. EPA) when the residue left over is less than2.5 cms at bottom or less than 3% ( for size less than 412.5 lits) and less than 0.3 % (for size more than 412.5 lits). An empty container may be classified as hazardousdepending on the nature of the material it contained. Guidelines for cleaning emptychemical container (SHE-TSOH-04-1322) shall be reffered for empty chemicalcontainer cleaning, reuse and disposal.

7.7 Guidelines for Chemicals Waste Management

7.7.1 Waste management shall be based on the principle of waste minimisation, followingthe waste management hierarchy of source reduction, reuse, recycling/recovery anddisposal. KNPC solid waste management document SHE-ENVP-03-0006 shall berefered for details.

7.8 Emergency Response

7.8.1 Pre emergency plan shall be developed for emergencies like fire, spill,chemical exposure etc. before handling of hazardous chemicals. Equipment shall bemaintained in the area to assist emergency response personnel e.g., eyewash andsafety shower, fire fighting equipment and personal protective equipment. MSDSshall be available for reference. Employees shall be trained to handle emergencies.In case of emergency contact ECCC through telephone 888.

7.9 Chemicals with Specific Hazards

8.0 Working with Flammable/Combustibles

8.1.1 General Safety Measures

8.1.1.1 Common flammable and combustible liquids are crude oil, coal tars,hydrocarbons, alcohol, and their by-products.

8.1.1.2 Manufactured liquids and fluid commodities which contain flammableliquids, such as paints, floor polish, cleaning solutions, dryers and varnishes shall beconsidered as flammable liquids and classified according to the flash point of themixture.

8.1.1.3 Precautions pertaining to their handling and use differ according to their flash points,volatility, and the amount of flammable liquid within the mixture. MSDS, operationmanual, etc. stipulate these requirements.

8.1.2 Ignition Sources

8.1.2.1 Smoking and carrying of matches, lighters and other spark or flame producing devicesshall not be permitted in a building or area where flammable liquids are stored,handled, or used. The extent of the restricted area will depend on the type of


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products handled, the design of the building, and local conditions. Suitable NOSMOKING and other signs shall be posted in buildings, and areas where smoking isprohibited.

8.1.3 Static Electric ity

8.1.3.1 Static electricity is a surface phenomenon due to electron exchange between twocontacting surfaces. When the two surfaces are in close proximity to each other, thenegative charge of excessive electrons on one surface is neuatralized the positivecharge of the electron deficient surface. When the two surfaces are separated, theaccumulated charge has no place to go, and is called static electricity. Theaccumulated charge on a given surface, because of its high potential, can flow to anear by conducting object, and if the magnitude of the charge is large enough, cangenerate spark which may ignite a potentially flammable mixture of gases.

8.1.3.2 Static electricity is generated by the contact and separation of dis-similar materials. For example, static electricity is generated when a fluid flowsthrough a pipe or from an orifice into a tank.

Figure 8.1 Recommended Practice on Bonding and Grounding

Hose may be either conducting ornon-conducting

Conductive nozzle incontact withcontainer- no otherbonding necessary

Hose may be eitherconducting or non-conducting

Metal plate bond the twocontainers

Metalcontainers

Metal plate bond the pump andthe drum

Nozzle not in contact- a bond wire is necessary except where containers are inherentlybonded together

Metal Strips fastened tofloor


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8.1.3.3 Grounding and bonding of flammable liquid containers shall be provided to preventstatic electricity causing a spark as in Figure.

8.1.3.4 To avoid a spark from discharge of static electricity during filling operations, a wirebond shall be provided between the storage container and the container being filled,unless a metallic path between the containers is otherwise present.

8.1.3.5 Above ground tanks used for storage of flammable liquids shall be properly grounded.Ground wire is preferred to be uninsulated, so it may be easily inspected formechanical damage. Petroleum liquids are capable of building up electrical chargeswhen they flow through piping or agitated in a tank or a container, or subjected tovigorous mechanical movement such as spraying or splashing. Grounding wire shallbe provided to drain off this static charge to ground as fast as it is generated.

8.1.3.6 High static charge shall be controlled by reducing the flow rates, avoiding violentsplashing with side-flow fill lines and use of relaxation time.

8.1.4 Electrical and Electron ic Equipment

8.1.4.1 Electricity is a common source of ignition where flammable vapors exist. Hence,proper type of electrical equipment for these atmospheres (e.g. Explosion proof,Intrinsically safe) shall be installed and they shall be properly maintained as perhazard area classification.

8.1.5 Health and Flammability Hazards

8.1.5.1 Most of flammable vapors are heavier than air and it can flow into pits, tank openings,confined areas, and low places in which they contaminate the normal air and, thuscause a toxic as well as explosive atmosphere. Oxygen deficiency may occur inclosed containers, such as a tank, which has been closed for a long time and in which

rusting has consumed the oxygen.

8.1.5.2 All containers shall be ventilated and tested for flammable, toxic and oxygen deficientatmosphere before man entry or any work.

8.1.6 Bulk loading Road Tank Vehicles

Bulk loading and road tank vehicles shall be as per company approved procedureswritten separately

8.1.6.1 Vehicles are to be loaded only with the class of products for which they are designedand authorized to carry.

8.1.6.2 The driver shall be aware of the hazards and trained for emergency actions. MSDSand minimum required emergency equipment shall be available in the cabin.

8.1.7 Containers and Portable Tanks for Handling Flammable Liquids

8.1.7.1 General

8.1.7.1.1 This Section shall apply only to the storage of flammable orcombustible liquids in drums or other containers not exceeding 60 US gallons (227 lt.)individual capacity and those portable tanks not exceeding 660 US gallons (2500 lt.)individual capacity. Flammable and combustible liquid containers shall be inaccordance with Table 8.1.

8.1.7.1.2 Each portable tank shall be provided with one or more approveddevices installed in the top with sufficient emergency venting capacity to limit internalpressure under fire exposure conditions.


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Table 8.1 Maximum Allowable Size of Containers and Portable Tanks

Flammable Liquids Combustible Liquids

Container TypeClass I A Class I B Class I C Class II Class III

Glass or approvedplastic

1 pt 1 qt 1 gal 1 gal 1gal

Metal (other than DOTSpecifications)

1 gal 5 gal 5 gal 5 gal 5 gal

Safety cans 2 gal 5 gal 5 gal 5 gal 5 gal

Metal drums(DOT specifications)


Approved portabletanks


8.1.7.2 Storage Cabinet

8.1.7.2.1 Not more than 60 US gallons of Class I or II liquids nor more than 120 US gallons(454 lt.) of Class III Liquids may be stored in the storage cabinet. The cabinet shallbe of approved type.

8.1.7.3 Storage Room

8.1.7.3.1 Storage rooms shall comply with the following specifications:a. Inside every storage room there shall be one clear aisle at least 3 feet (1

meter) wide. Containers over 30 US gallons (113.5 lt) capacity shall not bestacked one upon the other. Storage room shall be provided with approvedtype of natural or mechanical exhaust ventilation system.

b. Storage room shall not have a door that opens into that portion of the building

used by the public.

8.1.7.3.2 Dispensing of flammable liquid shall be by approved pump on self-closing faucetonly. Construction, electrical wiring and ventilation of the room shall be suitable forarea classification.

8.1.7.4 Storage Inside Buildings

8.1.7.4.1 Egress

Flammable or combustible liquids, shall not be stored so as to limit use of exits, stairways orareas normally used for the safe egress of people.

8.1.7.4.2 Office Occupancies

Storage shall be prohibited except for quantities required to operate office equipment. Suchstorage shall be in closed metal containers and stored in a storage cabinet or in safety cans.

8.1.8 Flammable and Combustible Liquid Warehouses or Storage Buildings

8.1.8.1 The total quantity of liquids within a building shall not be restricted but thearrangement of storage shall comply as shown.

8.1.8.2 Containers in piles shall be separated by pallets or dunnage(mats) where necessaryto provide stability and to prevent excessive stress on container wall.


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8.1.8.3 No pile shall be closer than 3 feet (1m) to the nearest structural beamobstruction and shall be 3 feet (1m) below sprinklers or other overhead fire protectionsystems.\

8.1.8.4 Aisles of at least 3 feet wide shall be provided where necessary for reasons of accessto doors, windows or emergency equipment.

Table 8.1 Indoor Container Storage

Maximum per pile

Protected Storage Unprotected StorageClass ofLiquid

Storage Level Gallons 55 GalDrums

Gallons 55 GalDrums

I A Ground & Upper Floors 2,750 50 660 12

I B Ground & Upper Floors 5,500 100 1,375 25

I C Ground & Upper Floors 16,500 300 4,125 75

Ground & Upper Floors 16,500 300 4,175 75II

Basement 5,500 100 Not Permitted

Ground & Upper Floors 55,000 1000 13,750 250III

Basement 8,250 450 Not Permitted

Note:1. Class 1 liquid shall not be stored in basements.2. When 2 or more classes of materials are stored in a single pile, the maximum gallonagespermitted in that pile shall be the smallest of the 2 or more separate maximum gallonages.3. Aisles shall be provided so that no container is more than 12ft. from an aisle. Main aislesshall be at least 8ft. wide and side aisles at least 4 ft. wide.4. Each pile shall be separated from each other by at least 4 ft.

8.1.9 Storage Outside Buildings

Storage outside building shall confirm to the table .

Table 8.2 Outdoor Container Storage

Class Maximum perpile(See note 1)

Distancebetween piles(See note 2)

Distance to propertyline that can be builtupon(See notes 3 & 4)

Distance tostreet, alley orpublic way(See note 4)

US GAL FT. FT. FT.I A 1,100 5 20 10

I B 2,200 5 20 10

I C 4,400 5 20 10

II 8,800 5 10 5

III 22,00 5 10 5

Notes:1. When 2 or more classes of materials are stored in a single pile, the maximum gallonage inthat pile shall be smallest of the 2 or more separate gallonages.2. Within 200 ft. of each container, there shall be a 12ft. wide access way to permit approachof fire control apparatus.

3. The distances listed apply to properties that have protection for exposures as defined. Ifthere are exposures and such protection for exposures does not exist, the distance in column4 shall be doubled.


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4. When total quantity stored does not exceed 150 percent of maximum per pile, thedistances in columns 4 and 5 may be reduced 50 percent, but not less than 3 ft.

8.2 Flammable Solids

Flammable solids such as sulfur and coke are handled in KNPC. Whilesome safety features are bulit-in, it requires maintaining these in proper condition and goodsafety practices of employees to avoid fire or explosion.

8.2.1 General Precautions

8.2.1.1 The dust content of the flammable solid in air must be kept below thelower explosive limit (i.e. it should not obscure vision at 5ft distance or less). Waterspray system shall be readily available.

8.2.1.2 In addition to right enclosures and dust collection systems, good plant housekeepingshall be maintained.

8.2.1.3 All sources of ignition shall be excluded from the area of a potentially explosive dust.The no smoking rule shall be rigidly enforced.

8.2.1.4 Wiring, lights and switches shall be in compliance with area classification.

8.2.3 Special Precautions

8.2.3.1 Spills in conveyor systems shall be cleaned as and when it occurs. Dust should not beallowed to rub against the moving parts.

8.2.3.2 Crew for cleaning shall be continuously in attendance during loading. After completionof loading, entire system shall be thoroughly cleaned.

8.2.3.3 Static electricity shall be prevented from accumulating by using antistatic material orany suitable method.

8.2.3.4 Substances, which give off flammable gases on contact with water, shall be stored indry storage facilities.

8.2.3.5 Substances which are liable to spontaneous ignition shall be stored in sealed closedand leak proof containers and underwater or in an inert atmosphere.

8.3 Toxic Materials

8.3.1 Storage

8.3.1.1 If any container is found to be leaking it has to be disposed by an approved disposalmethod only (Refer MSDS). Lids of the containers shall be properly closed.

8.3.1.2 Toxic materials shall not be stored near the sources of food or water etc. Food items,drinks, cigarettes etc. shall not be brought into storage rooms of toxic materials.Eating, drinking and smoking inside the storage rooms shall be strictly prohibited.

8.3.2 Handling

8.3.2.1 Handling of all toxic materials shall be done using appropriate protective equipment(Refer MSDS). In addition, tools used for handling the toxic materials or containers oftoxic materials shall not be used for any other purpose before cleaning properly.

8.3.2.2 All contaminated clothes and tools to be cleaned at a separate cleaning room. Clothesworn during the working time shall not be worn afterwards.


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8.4 Corrosive Materials

8.4.1 Corrosive materials which can react with the skin causing burns similar to thermalburns, and/or which can react with metal causing deterioration of the metal surface.Acids and bases are corrosives (e.g. Hcl, H2SO4, and Caustic).

8.4.2 Following are special precaution for working with corrosives:a. Containers and equipment used for storage and processing of

corrosiveb. Materials shall be corrosion resistant.c. Eye protection, chemical handling suit and rubber gloves shall be usedd. When handling corrosive materials.e. When mixing concentrated acids with water, add the acid slowly to Water.

Never add water to acid.f. Acids and bases should be stored separately from each other. Organic acids

should be stored with flammable materials, separate from oxidizers and oxidizingacids.

g. An eyewash and safety shower shall be readily accessible to areaswhere corrosives are used and stored. In the event of skin or eyecontact with corrosives, immediately flush the area of contact with cool water for15 minutes. Remove all affected clothing. Seek medical assistance.

8.5 Radioactive Materials

The section shall be read in conjuction with the KNPC InspectionProcedure IC-37: safe Practices for Industrial Radiography and IC-38: Procedure forSafe Transportation of Radioisotopes. KNPC Inspection shall ensure the following;

The following basic rules shall be strictly enforced:

a. The ionising radiation sources shall not be left unattended.b. Radiation film badge Dose Meter shall be used.c. The exposure area shall be identified, barricaded by rope or other effective

means and radiation warning signs posted.d. Employees shall ensure availability of radiation meter at work site of radiography.e. Supertidenent Inspection & Corrosion shall be given 12 hours prior

notice before starting any radiography work inside refinery.

8.5.1 Storage

8.5.1.1 When not in use or transit, the containers shall be kept in the locked storage pit so asto minimize the risk of their coming into the possession of unauthorized and untrainedpersons.

8.5.1.2 The storage pit shall be surrounded by a fence on which warning notices are posted.The store shall be under the supervision of the authorized person who is responsiblefor keeping the source records.

8.5.2 Personnel Safety

8.5.2.1 Only authorized personnel holding valid Radiation Work PermitLicense issued by Ministry of Health/Radiation Protection Divisionshall handle radioactive material.

8.5.2.2 The following safety equipment sahll be used when radiation work isto be executed:

a. Film badgesb. Radiation dose rate meter( Survey meters)

c. Pocket Dose meter(Optional)


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8.5.3 Working on Site

8.5.3.1 EnclosureWhere reasonably practicable, the radiography shall be carried out in a suitableenclosure, having a fence incorporating a lockable gate which must be kept lockedwhilst radiography is in progress. All except authorized persons will be excluded fromthe enclosure. When using Gamma-Ray sources, the dimensions of the enclosureshall depend on the type of equipment used and the nature or activity of the beam inrelation to the article radiographed. Where X-rays are used these dimensions shall begoverned by the operating conditions of voltage & current; other factors include beamfiltration, the effectiveness of any collimator used to limit the size and direction of theuseful beam. In both processes, there will be some attenuation of the radiation by thematerial of the work-place itself and local shielding such as concrete blocks or leadscreens. The enclosure shall be adequately marked with suitable radiation warningsigns when ionizing radiation are about to be used.

8.5.3.2 Suitably Marked AreaWhere it is not reasonably practicable to use a radiation enclosure, and the work hasto be carried out on site, steps shall be taken to provide a suitably marked areaencircled by a rope barrier. The barrier shall be set up at 0.25 millirems per hourdistance from the source and shall exclude all except authorized persons.

8.5.3.3 Warning SignalsIn all cases adequate warning to all persons in the vicinity shall be given by lamps oraudible signals or both when a sealed source is about to be exposed or when an X-ray machine is about to be energized. In the case of X-ray machine it is mandatorythat the means for giving warning shall be integrated with control circuitry, so thatthey operate automatically, and the equipment shall be unable to function unless theyare so connected.

8.5.3.4 Dose Rate Measurement

Measurement shall be made with an appropriate Dose Rate meter during radiographyto ensure that dose rate at the barrier does not exceed 0.25 millirems per hour.

8.5.3.5 General Precautions

The average persons knowledge of radiation and its hazards is verylimited. Therefore it is not enough to erect barriers and provide warningsignals just to comply with the regualtion. The radiographer or anassistant shall maintain a strict vigil to prevent unauthorized personsentering the area. If this cannot be done, work involving ionizingradiation shall cease until these persons can be persuaded to keep out.

8.5.3.6 Monitoring Dose Rate Meters

The meter shall be used to achieve the following objectives:a. To check initially that the safety barriers are positioned where the Doserate is not greater than 0.25 millirems per hour.

b. To monitor the Dose Rate at safety barriers, particularly when theradiographic technique varies,

c. To check that a source exposure container is fully closed after use or thatsource is fully retracted as appropriate.

d. To help locate a lost source, and monitor working conditions.8.6 Special Precautions for Working with Oxidizers

8.6.1 Oxidizing materials which react with other substances by accepting electrons andundergoing reduction. This reaction may result in fire or explosion. The intensity ofthe reaction depends on the oxidizing- reducing potential of the materials involved.

Oxidation reactions are the most frequent cause of chemical accidents (e.g. Nitrate,Chlorate, Permanganate, and Peroxide).


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8.6.2 Following are special precaution for working with oxidizersa. Knowledge of the reactivity of the materials involved in the experiment or

process.b. Assure there are not extraneous materials in the area which could become

involved in a reaction.c. Store properly, away from organic materials, flammable materials.

8.7 Working with Peroxidizables

8.4.1 Peroxidizables material reacts with oxygen to form peroxides which can explode withimpact, heat, or friction such as removing a lid. Since these chemicals may bepackaged in an air atmosphere, peroxides can form even though the container hasnot been opened. Examples of peroxidizables include ethyl ether, tetrahydrofuran,isopropyl ether, liquid paraffin (alkanes), and olefins (alkenes).

8.4.2 The following precautions are required along with other precautions similar toflammables:a. Date all peroxidizables upon receipt and upon opening. Unless an inhibitor has

been added by the manufacturer, materials should be properly disposed of after18 months from the date of receipt or 3 months from the date of opening.

b. Do not open any container which has obvious crystal formation around the lid.

8.8 Working w ith Carcinogens

8.8.1 Carcinogens are substance capable of producing cancer, mutations of genesresulting in irregular, uncontrollable growth of abnormal cells in humans.

8.8.2 Following are special precaution for working with carcinogensa. Identify all work and storage areas where chemical carcinogens are present withappropriate signs: Danger Chemical Carcinogen Authorized Personnel Only.b. Limit access to all work and storage areas where chemical carcinogens are

present.c. Extreme care should be taken to avoid aerosols.d. Whenever possible work under a hood.e. Eating, drinking, smoking and food storage should be prohibited where chemicalcarcinogens are present.

9.0 Hazard Communication

9.1 Material Safety Data Sheets (MSDS)

Policy and procedures for MSDS as documented in MSDS policy and procedures/documentshall be followed. MSDS shall be readily available to personnel in each area where chemicalsare used. Personnel must know where to find MSDS and how to read them. It shall beavailable for reference by the following people:

a. All employees for information regarding chemical identity, health effectsof exposure, handling precautions, and other hazard information.

b. Occupational health resources, to plan and evaluate handling precautions, airbornechemical monitoring, and respiratory protection.c. Emergency response personnel, for information related to spill, fire and

explosiond. People responsible for control measures medical personnel, for evaluating health effectsand planning treatment for overexposure

9.2 Labeling and Marking of Hazardous Materials

Containers or systems that hold hazardous materials shall display name of the material andthe hazards of its contents by labeling and marking. This includes fixed storage, portable


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tanks, modules, drums, cans, bottles and tankers. Marking shall be according to Kuwait EPAregulation (Appendix No.10-3). Labels shall contain the following information.a. Name, address and telephone number of the person responsible for

supplying the substance;b. Name of the substance or the trade name of the preparation;c. For a preparation, the constituents;d. Risk and safety measures.

9.3 Signage

All areas whrere chemicals are stored, handled or used shall be sign posted as per KNPCsign procedure. The symbols shall be in accordance with Kuwait Environmental PublicAuthority. Text shall be in accordance with appropriate KNPC regulations.

10.0 Training

Employees shall be provided with information and training to ensure that they are apprised ofthe hazards of chemicals in their work area. Such information shall be provided at the time ofan employee's initial assignment to a work area where hazardous chemicals are present andprior to assignments involving new exposure situations.

The training shall include:a. KNPC chemical hazard management Planb. TLV of hazardous chemicalsc. Signs and symptoms associated with exposures to hazardous chemicalsd. The location and availability of known reference materials such as MSDS and how to readtheme. Methods and observations that may be used to detect the presence or release of ahazardous chemical measures to protect from hazardous chemicals.f. The physical, chemical and health hazards of chemicals in the work areag. Measures employees can use to protect themselves from these hazards

h. Emergency procedures for reporting and negotiatingi. Waste management issues

It shall be the responsibility of the custodian superintendent to make sure that all employeeshave been identified (including contract personnel) and training has been arranged for them.Employees (including contractors) regularly handling chemicals shall be provided one dayintensive training.

Sl#

Group Jobs Length Record Content

1 Regular(Field)

Operator, TankTruck Driver,Laboratory,

Foreman,Technician,Mechanic,Supervisor

1 day TrainingPassport

Knowledge of chemicals in use& hazards, MSDS use, hazardcontrol, emergency

preparedness, wastemanagement

2 Occasionallycoming incontact

Section Head,Superintendent,Engineer,Manager

day Knowledge of chemicals in use& hazards, MSDS use, hazardcontrol, emergencypreparedness, wastemanagement

3 Office Staff 1 hr Hazard awareness

4 Janitorial 1 hr TrainingRecordSheet

Hazard awareness


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11.0 Exposure Assessment and Medical Surveillance

All sites handling chemicals shall be routinely monitored. Exposure assessment shall becarried out as per KNPC exposure assessment program.

All employees working with hazardous chemicals shall receive medical attention under thefollowing circumstances:a. When the employee develops signs and/or symptoms that may be associated with ahazardous chemical to which the employee was exposed.b. When routine monitoring reveals an exposure above 50% TLV.c. When an event takes place in the work area such as a spill or leak, explosion or otheroccurrence resulting in the likelihood of a hazardous exposure.

12.0 Standard Operating Procedures

Standard Operating Procedures (SOPs) shall be developed by individual work group specificto each chemical. Development of SOPs shall be the responsibility of the custodiansuperintendent. SOPs shall describe the following:a. Hazard control (engineering & administrative) measures to be used.b. Personal protective equipment that to be worn.c. Available health and safety information resources and location.

d. Decontamination procedures, including proper waste disposal practice.

13.0 Document Contro l

Each division at KNPC refineries shall maintain auditable records, to document its compliancewith this plan. Training and purchase records must be retained in compliance with KNPCrecord management system. Their retention times shall be 5 years.

14.0 Audit Requirements

Each operation at KNPC refineries shall establish and maintain a system for auditingcompliance against this plan. Audit findings shall be documented and a system established toensure that findings are appropriately addressed. Compliance to this procedure shall beaudited annually by Superintendent Safety and Fire with custodian area superintendent. Auditfindings shall be documented and appropriately addressed.

15.0 Renewal Process

This plan shall be reviewed and revised as necessary at a minimum interval of 3 years fromthe date of the last revision or to reflect changes.

16.0 Deviation ProcessDeviations from this procedure shall be authorized by Manager, Safety, Health and

Environment after consultation with Technical Support Division. Deviations shall bedocumented, and the documentation must include the relevant facts supporting the deviationdecision. Deviation authorisation shall be reviewed periodically and no less frequently thanevery 3 years.


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Append ix A: Chemical Purchase Hazard In formation Form*Kindly complete this form with the best possible answers to your knowledge.

Sl.# HAZARD EVALUATION REMARKS

1 What is the chemical?

2 Why is the chemical required?

3 Are there alternatavive chemicals that could beused?

4 Justify that the selected chemical is least toxicamong alternative chemicals.

5 What is the hazard classification (see definitions) ofchemical?

6 Is MSDS of the chemical available at KNPC?

7 Has an operating procedure specific to chemicalbeen prepared?

8 What control measures are suggested?

9 Has any hazard communication requirement been

specified?10 What training requirements have been specified?

11 What waste handling methods have beensuggested?

11 Have any emergency procedures been prepared?

12 Suggested work areas to be monitored?

13 Which employees exposures should be monitored?

* to be completed by indenter and sent to Technical Support, Safety, Health and Environment

Name: ID: Signature: Date:

Remarks (OH Section):

Approved: Superintendent, Technical Support, Safety, Health & Environment

Note 1: this form to be completed by indenter of any chemical (Technical Support Division canprovide assistance)Note 2: no purchase order shall be issued without the approved copy of this form


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APPENDIX B: Hazmat Labels as mentioned in Kuwait Environmental publ ic Author ity(KEPA). The same is applicable for KNPC

Flammable Gas Flammable Liquid Flammable Solid

Explosive Combustible Dangerous

Corrosive Toxic Infectious

Oxidizer Radioactive Non-Flammable Gas

Marine Pollutant Environment Hazard Dangerous when Wet


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APPENDIX C:Incompatible Chemicals

Chemicals Keep out of contact with

Alkaline metals such aspowdered aluminum or

magnesium, sodium,potassium, etc.

Carbon tetrachloride or other chlorinated hydrocarbon, carbondioxide and the halogens.

Acetic Acid Chromic acid, nitric acid, hydroxyl compounds, ethyleneglycol, perchloricaid, peroxides, permanganates.

Acetylene Chlorine, bromine, copper, fluorine, silver, mercury.

Ammonia, anhydrous Mercury (In manometers for instance) chlorine, calciumhypochlorite, iodine, bromine, hydrofluoric acid anhydrous.

Ammonium nitrate Acids, metal powders, flammable liquids, chlorates, nitrates,sulfur, finely divided organic or combustible materials.

Aniline Nitric acid, hydrogen peroxide.

Bromine Same as for chlorine.

Carbon activated Calcium hypochlorite and all oxidizing agents.

Copper Acetylene hydrogen peroxide.

Chlorates Ammonium salts, acids, metal powders, sulfur finely dividedorganic or combustible materials.

Chromic acid Acetic acid, naphthalene, camphor, glycerin, turpentine,alcohol and flammable liquids in general.

Chlorine Ammonia, acetylene, butadiene, butane, methane, propane(or other petroleum gases), hydrogen, sodium carbide,turpentine, benzene, finely divided metals.

Chlorine dioxide Ammonia, methane, phosphine, hydrogen sulfide.

Cumene hydroperoxide Acids Organic or inorganic.

Flammable liquids Ammonium nitrate, chromic acid, hydrogen peroxide, nitricacid, sodium peroxide, and the halogens.

Fluorine Isolate from everything.

Hydrocyanic acid Nitric acid, alkalis.

Hydrogen peroxide Copper, chromium, iron, most metals or their salts, alcohol,acetone, organic materials, aniline, nitro-methane, anyflammable liquid, combustible materials.

Hydrofluoric acid, anhydrous Ammonia, aqueous or anhydrous.

Hydrogen sulfide Fuming nitric acid, oxidizing gases.

Hydrocarbons (Butane,propane, benzene, gasoline,turpentine, etc.)

Fluorine, chlorine, bromine, chromic acid, sodium peroxide.


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APPENDIX C:Incompatible Chemicals (Contd.)

Chemical Keep out of contact with

Iodine Acetylene, ammonia (aqueous or anhydrous) hydrogen.

Mercury Acetylene, luminic acid, ammonia.

Nitric acid (concentrated) Acetic acid, aniline, chromic acid, hydrocyanic acid, hydrogensulfide, flammable liquids, flammable gases.

Oxalic acid Silver, mercury.

Perchloric acid Acetic anhydride, bismuth and its alloys, alcohol, paper,wood.

Potassium Carbon tetrachloride, carbon dioxide, water.

Potassium chlorate Sulfuric and other acids.

Potassium perchlorate (seealso Chlorates)

Sulfuric and other acids.

Potassium permanganate Glycerin, ethylene, glycol, benzaidehyde, sulfuric acid.

Silver Acetylene, oxalic acid, tartaric acid, fulminic acid, ammoniumcompounds.

Sodium Carbon tetrachloride, carbon dioxide, water

Sodium Peroxide Ethyl or methyl alcohol, glacial acetic acid, acetic anhydride,bensaldehyde, carbon disulfide, glycerin, ethylene glycol,ethyl acetate, methyl acetate, furfural.

Sulfuric acid Potassium chlorate, potassium perchlorate, potassiumpermanganate (or such compounds with similar light metals,as sodium, lithium, etc.)


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APPENDIX D:Chemical Hazards Management flowchart

ORGANIZATIONPROCESS DESCRIPTION Indenting/ user

DivisionVendor Purchase

DivisionWare houseDivision

Technicalsupport

SH&E

Safety & Fire

Requirement of chemicals/ saferalternatives, hazardsidentification, chemicalpurchase hazards informationform (CPHI Form)

Approval of CPHI form

Supply of MSDS in KNPCformat for approval

Storage of chemicals

Chemical hazardcommunication

Use of Chemicals

Disposal of chemicals

Emergency handling

Exposure assessment andmedical surveillance

NewChemicall

Old Chemical

Storage/

handling

re uirement

CPHI Form

Training

MSDSSign posting

Labeling

Chemical

handling

Emergency

handling

Exposure

assessment

Chemical

Indenting

Disposal of

chemical

Approved

CPHI Form

& MSDS

CPHI Form

approval

Supply of

MSDS

New

chemicalodering

Supply ofnew

chemical

MSDSapproval

chemical hazard mgnt_program (www.ebookbyte.com)

Documents