hazards and risk assesment.pdf

8/10/2019 Hazards and Risk Assesment.pdf

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DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 1 of 15

WORK INSCTRUCION

Department:

TITLE: Post-Wise Hazards & Risk Amassment

1.0 PURPOSE :

The purpose of this section is to familiarize the operator with some potential hazards in the

ammonia Plant and the equipment provided to control the hazards. The use of safe procedures

and the proper safety equipment is a help in conducting our business, not a hindrance it is

essential that the operator develop positive safety attitude. This will occur only when he firmly

believe that the safe way is the only way he can properly do his job. The operator is not only

responsible for his own safety he has a responsibility to conduct himself in such a manner so as

not to jeopardize the safety of his fellow employees. The Operator is the proprietor of the plant.

He is operating and as such has the prime responsibility for the safety of all who enter his work

area.

2.0 SCOPE:

Following procedure will help for the hazards identification and their risk assessment at ammonia plat post-wise.

3.0 DE-ARATOR AREA HAZARDS

Sr.No Hazards Involved Description

1 Chemicals

Anti corrosion, oxygen removal and Ph control chemicals arebeing used in BFW and steam system. The exposure can cause

serious health problems with eyes or skin. Use proper personal

protective while working in the BFW and steam systems. In

case of a contact with the chemicals wash with plenty of water

and sort medical help.

Hydrazine 35%

W/W (N2H4)

Safety Profile: It is colorless liquid, causes eye burns, and may cause blindness.

Causes skin and respiratory tract irritation

Precautions:Handle only when wearing complete protective equipment, including

chemical suit, rubber gloves, boots, and goggles. Avoid accidental contact with skin

and eyes. Do not breathe vapor .Use only in well ventilated areas where exposure

level is at or below 0.1 ppm.

First Aid: In case of skin and eye contact- immediately wash with clean water for 15

min. If ingested wash out mouth thoroughly with water and continue to drink

plenty of water. If inhaledremove to fresh air. Refer to FFCL medical Center.

ROUTE PREPARED BY REVIEWED BY APROVED BY REFERENCE

Name SAQIB RAOUF

QMS : 5.5.1HSE : 4.4.1

Date 28-08-14

Desig./Sign.


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Tri-sodium

Phosphate

(Na3PO4)

Safety Profile: it is odorless non-combustible powder. Inhalation, Eye and Skin

Contact may cause irritation and discomfort, Avoid breathing. Overexposure can

cause lung disease or asthma.

Precautions: Dont wash spills into water ways, collect by vacuuming and place in

labeled containers for proper disposal. Avoid handling method creating excessivedust. Use hygienic methods, dont eat and drink while handling this compound.

First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean

water for minimum 15 minutes. Prompt irrigation of the eyes with clean water

prevents serious eye injury. Skin Contact quickly wash with plenty of water with

soap. Remove contaminant clothing. Inhalation- If dust is inhaled, Move to fresh air.

Ammoniacalwater

Safety Profile: it is solution of ammonia, in case of contact can cause irritation to

skin, eyes and upper respiratory tract; headache, nausea. Inhalation of vapors may be

fatal by causing glottis to spasm and suffocation. Can have delayed effect after

moderate exposure.

Precautions: In case ofEye contact-hold eyelids open and immediately wash eyeswith clean water for minimum 15 minutes. Prompt irrigation of the eyes with clean

water prevents serious eye injury. In case of Skin Contact quickly wash with plenty

of water. Do not apply any ointments.

First Aid: If in contact with clothing, immediately remove contaminated clothing and

get under shower or any other source of water. Take care of attached skin (if any)

due to cryogenic action of ammonia.

2 Steam

Area comprises a small network of steam. Steam is used for

the operation of different steam turbines. There are many

steam headers of different pressures. Steam system operates

at every high temperature. There is a risk of burns if exposed

to high temperature and high pressure steam. Area operators

are advised to use special precautions and protective against

this hazard. Do not touch the naked steam piping. Use PPE

while taking samples and operating or attending maintenance

activities at steam

3Electricity

An electrical work permit to be obtained before any work is to

be performed on any electrical circuit. The electrical power

source should be turned off and lock out tag out procedure to

be strictly followed. Stay in contact with your shift supervisor

and Shift Co-coordinator to ensure that correct power source

or breaker has been turned off / disconnected / locked an

properly tagged. Work permit procedure and lock out tag out

procedures to be followed strictly. An incident will be recorded

if electrical job found in progress without wok permit, proper

authorization and proper isolation.

4 Nitrogen

Nitrogen is inert gas used as sealing media for condensing

turbines especially in this area .It is also used for purging

equipment. It is not poisonous or flammable but care must be

exercised when working on equipment that is being purged.

Adequate ventilation must be provided or appropriate

breathing devices worn. To breath an atmosphere high in

nitrogen could result in suffocation and death. Before entering

vessels that have been purged with nitrogen a check must be

made for proper oxygen concentration and an entry tape must

be cleared.


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4.0 REFORMING AREA HAZARDS


1 Explosive Mixture

Process and equipment in the area contain explosive gasesHydrogen, Methane, Ethane and ammonia. Explosive Mixtures

can exist when ever air or oxygen is in present in the system.

During startup purging procedures must be followed closely.

All equipment must be air free before hydrocarbons can be

allowed into the system. Follow the proper purging procedures

for commissioning of the system with Hydrocarbons.

Auto Ignition

Temp=538 C

LEL=5%

UEL=15%

METHANE (CH4)

Safety Profile: it is Colorless, odor less and tasteless gas. It is the major constituent

of natural gas. Highly flammable and explosive gas which forms inimitable mixtures

with air. It is a buoyant gas which may collect under roofs or ceilings forming

pockets of explosive gaseous mixture. Not toxic but a simple asphyxiate.

Precautions: Before any work is performed on vessels, piping or equipment that

have or could have contained methane in any concentration, they must be

thoroughly purged with nitrogen and then carefully checked with an explosivity

meter for the presence of flammable gas.

First Aid: A person asphyxiated by the Methane Should be removed to fresh air

immediately and kept warm and quiet until medical assistance can be obtained. If

the victim has stopped breathing, artificial respiration must be given immediately.

Auto Ignition

Temp=500 C

LEL=4%UEL=75%

HYDROGEN

Safety Profile: it is Colorless, odor less and tasteless gas. Highly flammable and

explosive gas which forms inimitable mixtures with air. It is a buoyant gas which may

collect under roofs or ceilings forming pockets of explosive gaseous mixture. Not

toxic but a simple asphyxiate.Precautions: Before any work is performed on vessels, piping or equipment that

have or could have contained hydrogen in any concentration, they must be

thoroughly purged with nitrogen and then carefully checked with an explosi-meter

for the presence of flammable gas. If a hydrogen rich gas leaks should develop from

equipment containing the gas at high temperature (e.g. primary reformer out let

pigtail) immediately apply steam directly on the source of the leak to stop or

prevent a fire. NEVER USE WATER

First Aid: A person asphyxiated by the Hydrogen Should be removed to fresh air

immediately and kept warm and quiet until medical assistance can be obtained. If

the victim has stopped breathing, artificial respiration must be given immediately.

Auto Ignition

Temp=609 C

LEL=12.5%

UEL=74.8%

CARBOB

MONOOXIDE

(CO)

IDLH=1200ppm

TWA=25ppm

Safety Profile: it is Colorless, odor less and Flammable gas. Mildly toxic byinhalation. Systematic effects on humans by inhalation. It can cause asphyxiation by

preventing hemoglobin from binding with oxygen. Acute cases of poisoning resulting

from brief exposure to high concentration seldom result in any permanent disability

if recovery takes place in time.

Precautions: Use forced ventilation to dilute concentrations around process

leaks.Use self contained breathing apparatus in concentrations above 50 ppm. Do

not work in confided spaces with combustion engines running unless there is

adequate ventilation.

First Aid: A person overcome by or exhibiting signs of carbon monoxide poisoning

must be removed to fresh air immediately and kept warm. Administer oxygen if

necessary until medical assistance can be obtained.


4/15


2 Steam

Area comprises a large network of steam generation and

steam consumer vessels and piping steam is being produced

and superheated in this area and is consumed for reforming

process Steam is also used for the operation of different steam

turbines. There are many steam headers of different pressures.

Steam system operates at every high temperature. There is a

risk of burns if exposed to high temperature and high pressure

steam. Area operators are advised to use special precautions

and protective against this hazard Do not touch the naked

steam piping Use PPE while taking samples and operating or

attending maintenance activities at steam.

3 Nitrogen

Nitrogen is inert gas used for purging of equipment. It is not

poisonous or flammable but care must be exercised when

working on equipment that is being purged. Adequate

ventilation must be provided or appropriate breathing devices

worn. To breath an atmosphere high in nitrogen could result insuffocation and death. Before entering vessels that have been

purged with nitrogen a check must be made for proper oxygen

concentration and an entry tape must be cleared.

4 Primary Reformer

Primary Reformer and surrounding areas contain serious fire

hazards. Draft is controlled in primary reformer to keep flames

confined inside the fire box, Loss of draft or a positive pressure

may result in a back fire and travel of flames to outwards from

openings causing serious burns an injury to personal working

in the area, Personal working in the area should be careful

about the hazard check draft and use proper personalprotective while climbing the primary reformer decks

5 BFW

Reforming area has steam generation network and Boiler feed

water is used to produce steam, BFW being used is of high

temperature. Any person exposed to high temperature BFW

will get serious burns. Proper Personal protective must be used

while working at steam generators and BFW circuits.

6 Leaks

Hydrogen and ammonia leaks can frequently be controlled

sufficiently to enable operators to shut off control valves, by

directing water hose stream on the leak. In severe Ammonia

leaks large volumes of water are needed. Warn all employeesin the area in which the leaks occur and in the surrounding

area which may be affected. Remove or control the possible

sources of ignition. In cases where leaking point cannot be

isolated use large volumes of water played directly on the

leaks and maintain contact unit the contents have been

discharged and the vessel or line is depressurized.

7 Mercury

Mercury (from thermometers, Manometers etc) should never

be allowed to come in contact with ammonia due to the

formation of explosive compounds. Get the area cleaned

immediately in case of a mercury spill.


5/15


8 Electricity




be strictly followed Stay in contact with your shift supervisor

and Shift Co-coordinator to ensure that Correct power source






9 Catalysts

Several catalysts are used in the area in Primary reformer,

secondary reformer, desulfurizer pre-reformer, HTSC and LTSC.

Dust from these catalysts is a serious health hazard Special

care must be taken and proper personal protectives must be

used while working with the catalysts. Catalysts are Pyrophoric

also such materials will burn spontaneously in the presence ofoxygen. Catalysts in the vessels are in reduced state and when

they are exposed to oxygen a violent reaction occurs which is

exothermic and produces heat. A fire could result causing

serious injury to personal working in the area and damage to

the equipment special precautions must be taken while

removing any catalyst from vessel or opening up nay catalyst

vessel. There might be migration of catalyst dust to the

catalyst vessel downstream equipment and piping Any such

build in the downstream circuits should also be watched while

opening up to atmosphere for repairs or inspection.

Hydro

Processing

Catalyst

(TK-261)

Safety Profile: it is odor less Non-combustible solid. Product Ingredients are NiO (1-

3%), MoO3 (7-13%) and Al2O3 (80-90%). insoluble in water however leaching may

occurs. Inhalation, Eye and Skin Contact may cause irritation and discomfort. Product

contains Nickel oxide which is carcinogenic and it has long term adverse effects on

aquatic environment.


labeled containers for proper disposal. Avoid handling method creating excessive

dust. Use hygienic methods, dont eat and drink while handling this compound.



prevents serious eye injury. In case of Skin Contact quickly wash with plenty of water

with soap. Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case

of ingestion seek medical attention

Sulphur

Absorption

Catalyst

(HTZ-5)

Safety Profile: it is odor less non-combustible solid. Product Ingredients are 99-

100% ZnO. Insoluble in water however leaching may occurs. Inhalation, Eye and Skin

Contact may cause irritation and discomfort. It has long term adverse effects on


Precautions:Dontwash spills into water ways, collect by vacuuming and place in









6/15


Sulphur

AbsorptionCatalyst

(ST-101)

Safety Profile: it is odor less non-combustible solid. Product Ingredients are 99-

100% ZnO. Insoluble in water however leaching may occurs. Inhalation, Eye and Skin

Contact may cause irritation and discomfort. Product contains Zinc oxide which is

carcinogenic and it has long term adverse effects on aquatic environment.

Precautions:Dontwash spills into water ways, collect by vacuuming and place in

labeled containers for proper disposal. Avoid handling method creating excessivedust. Use hygienic methods, dont eat and drink while handling this compound.






Steam

Reforming

Catalyst

(R-67-7H)

Safety Profile: it is odor less non-combustible solid. Product Ingredients are NiO

(15-20%), MgO (20-25%) and Al2O3 (55-60%).Insoluble in water however leaching

may occurs. Inhalation, Eye and Skin Contact may cause irritation and discomfort.

Nickel and Nickel Oxide compounds are carcinogenic in nature. Product containsNickel Oxide which is very toxic and has long term adverse effects on aquatic

environment.









Steam

Reforming

Catalyst

(RKS-2)

Safety Profile: it is odor less non-combustible solid. Product Ingredients are NiO (7-

13%), MgO (25-30%) and Al2O3 (60-70%).Insoluble in water however leaching may

occurs. Inhalation, Eye and Skin Contact may cause irritation and discomfort. Nickel

and Nickel Oxide compounds are carcinogenic in nature. Product contains Nickel

Oxide which is very toxic and has long term adverse effects on aquatic environment.






prevents serious eye injury. In case of Skin Contact quickly wash with plenty of waterwith soap. Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case


High

Temperature

Shift Catalyst

(SK-201-2)

Safety Profile: it is odor less non-combustible solid. Product Ingredients are Fe2O3

(80-90%), Cr2O3 (8-13%) and CuO (1-2%).Insoluble in water however leaching may


and Nickel Oxide compounds are carcinogenic in nature. Product contains Nickel

Oxide which is very toxic and has long term adverse effects on aquatic environment.










7/15


Low

Temperature

Shift Catalyst

(LSK)

Safety Profile: it is odor less non-combustible solid. Product Ingredients are Cr2O3

(40-50%), CuO (15-20%) , ZnO (25-35%).Insoluble in water however leaching may


and Nickel Oxide compounds are carcinogenic in nature. Product contains NickelOxide which is very toxic and has long term adverse effects on aquatic environment.









5.0 CATACARB AREA HAZARDS


1 Catacarb Solution

Catacarb solution is mixture of different chemicals which is

used to remove carbon di-oxide from the process gas.It is basic

and corrosive in nature. Use proper PPES while handling it.

POTASSIUM

CARBONATE

(K2CO3)

Safety Profile:Potassium carbonate is white deliquescent granular or translucent

powder with alkaline. It is non flammable, Irritating to eyes and respiratory system.

Repeated or prolonged skin contact may cause irritation Taste.

Precautions: Avoid skin contactuse rubber gloves, chemical splash suit. Avoid eye

contactuse goggles. Avoid inhalationuse dust mask.

First Aid: In case of skin contact- immediately brush off any powder and wash with

water. In case of Eye Contactwash with plenty of water. In case of Inhalation

blow nose clean and wash nostrils.

CATACARB 400

Safety Profile: it is proprietary mixture (organic) used in Catacarb.it Can explode if

heated under confinement. Hot organic Chemical vapors may spontaneously ignite

or explode when mixed with air, even at temperature below their published auto

ignition temperature. Irritating to eyes and respiratory system. Repeated orprolonged skin contact may cause irritation.

Precautions: Wear PPEs and portative equipments, handling in adequate

ventilation; dont breathe vapor mist or dust. Do not get in eyes on skin or clothing.

Dont swallow. Avoid contact with skin, eyes and clothing. After handling this product

wash hands before eating, drinking or smoking. if contact occurs, remove

contaminated clothing

First Aid: In case of skin contact- Immediately flush skin with plenty of water for at

least 15 min while removing contaminated clothing and shoes. In case of Eye Contact

Immediately flush eyes with water for 15 minutes while holding eyelids apart to

ensure flushing of entire surface. In case of Inhalation Moved to fresh air. If not

breathing give artificial respiration. Ingestion ingestion may cause pain, severeirritation, burns, nausea, vomiting, diarrhea, drowsiness, internal bleeding, coma and

even death.


8/15


Vanadium Pent

oxide (V2O5)

Safety Profile: It is non combustible, odorless orange powder. Inhalation, Eyeand Skin Contact may cause irritation and discomfort, Avoid breathing dust.

Overexposure can cause lung disease or asthma, headache and dry cough


labeled containers for proper disposal. Use rubber gloves, chemical resistant suit andSCBA. Avoid handling method creating excessive dust. Use hygienic methods, dont

eat and drink while handling this compound.

First Aid:In case of Eye contact-hold eyelids open and immediately wash eyes with

clean water for minimum 15 minutes. Prompt irrigation of the eyes with clean water

prevents serious eye injury. In case of Skin Contactquickly wash with plenty of

warm water. Remove contaminant clothing. Inhalation- If dust is inhaled, Move to

fresh air and consult with FFL Medical Centre. IngestionIn case of ingestion seek

medical attention

CATACARB De-

foamer WBU

Safety Profile: it is proprietary mixture (organic) used in Catacarb as Anti-Foamig

agent. Use water to cool containers exposed to fire. a direct stream of water cause

foaming. Irritating to eyes and respiratory system. Repeated or prolonged skincontact may cause irritation.

Precautions: Wear PPEs and portative equipments, handling in adequate

ventilation; wash thoroughly after handling. Do not get in eye skin contact. Avoid

prolonged or repeated skin contact. Dont swallow. Keep heat, fire and spark away.

For industrial use only. Emptied contains product residues (vapor, liquid) all labeled

hazard precautions must be observed.Avoid contact with skin, eyes and clothing.

After handling this product wash hands before eating, drinking or smoking. If contact

occurs, remove contaminated clothing.

First Aid: In case of skin contact- Immediately flush skin with plenty of water for at

least 15 min while removing contaminated clothing and shoes. In case of Eye Contact

immediately flush eyes with water for 15 minutes while holding eyelids apart to

ensure flushing of entire surface. In case of Inhalation Moved to fresh air. If not

breathing give artificial respiration. Ingestion If swallowed dont induce vomiting.

Rinse mouth with water. Dilute stomach content by drinking water. Never gave

anything by mouth to unconscious person.

2 Steam

Area comprises a network of steam and steam consumer

vessels. Steam is also used for the operation of different steam




steam. Area operators are advised to use special precautionsand protective against this hazard. Do not touch the naked

steam piping. Use PPE while taking samples and operating or


3 Electricity







properly tagged. Work permit procedure and lock out tag outprocedures to be followed strictly. An incident will be recorded




9/15


4 Nitrogen

Nitrogen is inert gas used for purging equipment It is not




worn. To breath an atmosphere high in nitrogen could result in

suffocation and death. Before entering vessels that have been



5 Hydrogen

The area contains huge quantities of Hydrogen. Hydrogen is a

highly flammable gas and it is present at high pressure in the

Unit. Hydrogen leaks are not easily seen and care must be

taken when working around equipment that contains

hydrogen. Hydrogen has the ability to auto ignite so an outside

ignition source is not necessary. Burning hydrogen is very

difficult to see. If a leak is suspected the operator must move

carefully so as not to come in contact with it. The leak and

explosively testing should be carried out regularly by theoperator to avoid a potential fire hazard in the area.

Explosively should be checked at and around the work place

before allowing any hot work. Steam should be applied

immediately at the point where leak is suspected to dilute the

explosive mixture. If such detected inform shift supervisor and

shift coordinator immediately.

6 Carbon Di-oxide

Safety Profile: it is Colorless, odor less and non flammable gas. A

simple asphyxiate gas. As an inert gas, it has no specific inherent

dangerous properties. Gases of this type have no specific toxicity

effect, but they act by excluding oxygen form the lungs.Precautions: Never enter a confined space / vessel without first

satisfying all the requirements of the confined space entry

certificate. Use self contained breathing apparatus when entering

vessels that contain high concentration of CO2.

First Aid: Inhalationa victim overcome by carbon dioxide must be

removed to fresh air immediately and referred to the FFCL medical

centre. If the victims breathing has stopped begin artificial

respiration.

7

NICKEL CARBONYAL(Ni(CO)4

Safety Profile: it is Colorless, potentially fatal if inhaled volatile

liquid. Severe fire and explosion hazard. Vapors are heavier than air

and may ignite at distance form source and flash back. Vapor and airmixture are explosive.

First Aid:In case ofeye contact-hold eyelids open and immediatelywash eyes with clean water for minimum 15 minutes. In case of skin

Contact quickly wash with soap and plenty of water for 15

minutes. Remove contaminated clothing. If inhaled; immediately

move from contaminated area; give artificial breathing if not

breathing. If Ingested: move to fresh air, if vomiting keep head

lower than hips to prevent aspiration. If person is unconscious turn

head to side and Immediately Refer to FFCL medical Center.

8 CatalystsMethanation catalyst is used in methanator to increase therate of methanation of CO and CO2


10/15


MethanationCatalyst (PK-7R)

Safety Profile: it is odor less Non-combustible solid. Product Ingredients are Ni (25-

30%), NiO (1-5%) and Al2O3 (60-70%).Insoluble in water however leaching may

occurs. Inhalation, Eye and Skin Contact may cause irritation and discomfort. Product

contains Nickel oxide which is carcinogenic and it has long term adverse effects on


Precautions: Dont wash spills into water ways, collect by vacuuming and place inlabeled containers for proper disposal. Avoid handling method creating excessive







6.0 SYNTHESIS AREA HAZARDS


1 Hydrogen





hydrogen. Hydrogen has the ability to auto ignite so an outside

ignition source is not necessary. Burning hydrogen is very



explosively testing should be carried out regularly by the

operator to avoid a potential fire hazard in the area.






2 Explosive Mixture

Process and equipment in the area contain explosive gases

Hydrogen Methane and ammonia. Explosive Mixtures can exist

when ever air or oxygen is in present in the system. During

startup purging procedures must be followed closely. All

equipment must be air free before hydrocarbons can be

allowed into the system. Follow the proper purging procedures

for commissioning of the system with Hydrocarbons.

3 Nitrogen









11/15


4 Steam

Area comprises a large network of steam generation and

steam consumer vessels and piping steam is being produced

and superheated in this area and is consumed for reforming

process Steam is also used for the operation of different steam

turbines. There are many steam headers of different pressures.Steam system operates at every high temperature. There is a


steam. Area operators are advised to use special precautions

and protective against this hazard Do not touch the naked



5 Leaks

Ammonia synthesized in synthesis section as well as anhydrous

ammonia is used as a refrigerant in refrigeration section.

Ammonia is a toxic gas under ambient conditions. Many parts

of a refrigeration section contain ammonia liquefied underpressure. Releases of ammonia have the potential for harmful

effects on workers and the public. If the ammonia is under

pressure, risk of exposure increases since larger quantities of

the refrigerant have the potential for rapid release into the air.

Also, some explosions have been attributed to releases of

ammonia contaminated with lubricating oil.

6 Ammonia

Safety Profile: It is Colorless, combustible gas (when escaping froma pressurized system may appear as white plume).Extremely

pungent odor, liquefied by compression. Very soluble in water. In

case of contact can cause irritation to skin, eyes and upperrespiratory tract; headache, nausea. Inhalation of vapors may be

fatal by causing glottis to spasm and suffocation. Can have delayed

effect after moderate exposure.

Precautions: In case of Eye contact-hold eyelids open andimmediately wash eyes with clean water for minimum 15 minutes.

Prompt irrigation of the eyes with clean water prevents serious eye

injury. In case of Skin Contact quickly wash with plenty of water.

Do not apply any ointments.

First Aid: If in contact with clothing, immediately remove

contaminated clothing and get under shower or any other source of

water. Take care of attached skin (if any) due to cryogenic action ofammonia.

7Perlite

It is cold insulation material used in cold box.

Safety Profile:It is white to off white granules, no odor. Visual only

(dust), No gas, vapors, or mist emitted. Perlite is a naturally

occurring mineral. In itself it is not a toxic mineral. This material

presents little threat for human health provided that the standards

of industrial hygiene.

Precautions: The use of engineering measure (e.g. local dust

extraction) is recommended to provide effective dust control in

order to ensure compliance with the current Occupational Exposure

Limits.

First Aid: The product is not primary irritant but eye contact may

cause irritation due to abrasion so rinse with plenty of water for 15

minutes. The product is not primary irritant but persistent skin

contact may cause irritation due to abrasion. Excessive inhalation of

product dust may give rise to temporary irritation of the respiratory


12/15


tract, as with any powders.

Electricity











9 CatalystsCatalyst is used in ammonia convertor that increases the ammoniasynthesis reaction.

S-300

Ammonia

Convertor

Catalyst (KM1-

R)

Safety Profile: Faint Smelly Ammonia in Solid, insoluble in water however leaching

may occurs. Product Ingredients are Fe (90-95%), Fe2O3 (1-4%), CaO (1-4%), K2O (0-

1%) and Al2O3 (1-4%).Contact with water may cause self heating and formation of

hydrogen; contact with air above 100C may cause self heating. Inhalation, Eye and SkinContact may cause irritation and discomfort. Product is very toxic and has long term

adverse effects on aquatic environment.


labeled containers for proper disposal. Avoid handling method creating excessive dust.

Use hygienic methods, dont eat and drink while handling this compound.

First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean water

for minimum 15 minutes. Prompt irrigation of the eyes with clean water prevents

serious eye injury. In case of Skin Contact quickly wash with plenty of water with soap.

Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case of ingestion

seek medical attention

7.0 COMPRESSOR AREA HAZARDS


1 Hydrogen





hydrogen. Hydrogen has the ability to auto ignite so an outsideignition source is not necessary. Burning hydrogen is very



explosively testing should be carried out regularly by the

operator to avoid a potential fire hazard in the area.






2 Mercury

Mercury (from thermometers, Manometers etc ) should never

be allowed to come in contact with ammonia due to the

formation of explosive compounds. Get the area cleaned

immediately in case of a mercury spill.


13/15


3 Nitrogen








4 Steam

Area comprises a large network of steam. Steam is used for

heating purpose as well as the operation of different steam




steam. Area operators are advised to use special precautionsand protective against this hazard Do not touch the naked



5 Electricity











6 Ammonia

Safety Profile: It is Colorless, combustible gas (when escaping froma pressurized system may appear as white plume).Extremely


case of contact can cause irritation to skin, eyes and upper

respiratory tract; headache, nausea. Inhalation of vapors may be



Precautions: In case of Eye contact-hold eyelids open andimmediately wash eyes with clean water for minimum 15 minutes.


injury. In case of Skin Contact quickly wash with plenty of water.

Do not apply any ointments.



water. Take care of attached skin (if any) due to cryogenic action of

ammonia.

7 Explosive Mixture

Process and equipment in the area contain explosive gases

Hydrogen Methane and ammonia. Explosive Mixtures can existwhen ever air or oxygen is in present in the system. During

startup purging procedures must be followed closely. All

equipment must be air free before hydrocarbons can be

allowed into the system.


14/15


8.0 STORAGE AREA HAZARDS


1 Ammonia

Safety Profile: It is Colorless, combustible gas (when escaping from

a pressurized system may appear as white plume).Extremely


case of contact can cause irritation to skin, eyes and upper

respiratory tract; headache, nausea. Inhalation of vapors may be



Precautions: In case of Eye contact-hold eyelids open and

immediately wash eyes with clean water for minimum 15 minutes.


injury. In case of Skin Contact quickly wash with plenty of water.Do not apply any ointments.



water. Take care of attached skin (if any) due to cryogenic action of

ammonia.

2Ammonia Storage

Tank

Releases of ammonia have the potential for harmful effects on

workers and the public. A larger quantity of ammonia is stored in

storage tank in this area.

3 Nitrogen


poisonous or flammable but care must be exercised whenworking on equipment that is being purged. Adequate


worn. To breath an atmosphere high in nitrogen could result in

suffocation and death. Before entering vessels that have been



4 Electricity











5 Steam

Area comprises a large network of LLP steam. Steam is used for

heating purpose. Steam system operates at every high

temperature. There is a risk of burns if exposed to high

temperature and high pressure steam. Area operators are

advised to use special precautions and protective against this

hazard .Do not touch the naked steam piping Use PPE while

taking samples and operating or attending maintenance

activities at steam.


15/15


6 Mercury

Safety Profile: This product is a clear, volatile, flammable liquid.

Has a slight alcoholic odor. Highly flammable. Vapors may form

explosive mixtures with air. The product causes irritation of eyes,

skin and mucous membranes. Toxic by inhalation, in contact withskin and if swallowed. Methanol can cause blindness. Causes

headache, drowsiness or other effects to the central nervous

system. Do not allow product to contact skin, eyes and clothing. Do

not breathe vapors.

Precautions: In case of spill or other release use personal

protective equipment. Ensure adequate ventilation. Remove all

sources of ignition. Stop flow of material, if this is without risk.

First Aid: In case of skin contact - Wash off immediately with soap

and plenty of water. Take off contaminated clothing and shoes

immediately. Wash contaminated clothing before re-use. Call a

physician immediately. In case of eye contact Rinse immediatelywith plenty of water, also under the eyelids, for at least 15 minutes.

Call a physician immediately. Move to fresh air in case of accidental

inhalation of vapors. If not breathing, give artificial respiration. If

breathing is difficult, give oxygen, provided a qualified operator is

available. Call a physician immediately.

9.0 DISTRIBUTION LIST:

Original : Unit Manger

Copy # 1 : CCR-1

Copy # 2 : Area

hazards and risk assesment.pdf

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