Regulation Safe Work Practice KNPC

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KUWAIT NATIONAL PETROLEUM COMPANY

Document no.:

HSE-TSOH-10-1363

Title:

Safe Work Practice On Entry & Cleaning Of Leaded Fuel Storage Tanks

Signature

Date

T. B. Ravi Industrial Hygienist

Authors

Subhash Malhotra Safety Engineer-HSE Tech. Support Ujwal Ritwik Sr. Specialist TPL – TPL – HSE HSE

Reviewer

Abdul Jabar Al-Qahtani Team Leader, Technical Support-HSE

Fahad Al-Dihani

Approver

Manager – Manager – HSE HSE

Document Custodian : Health, Safety & Environment Department Next Revision due: October 2013

2

October 2010

Revised to include Octel Guidelines and PPE Standards

1

June 1999

Revised and released for implementation

0

June 1994

Released for implementation

Rev.

Date

Ref. No.: HSE-TSOH-10-1363 (Rev : 2) Title: Safe Work Practice On Entry & Cleaning Of Leaded Fuel Storage Tanks

Description

Date of Issue: Oct. 2010 Next revision date: Oct. 2013


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Safe Work Practice On Entry & Cleaning Of Leaded Fuel Storage Tanks Contents Sl #

Topic

Page #

1.0

Introduction

3

2.0

Hazards Of Lead Alkyls

3

3.0

Selection Of Personnel

4

4.0

Respiratory Protection

5

5.0

Protective Clothing

6

6.0

Tank Cleaning

7

7.0

Tank Inspection

10

8.0

Marking Of Tanks

10

9.0

Disposal Of Leaded Sludge

10

APPENDIX-A: APPENDIX-A: Cleaning Cleaning Procedures Procedures And Personal Personal Protectio Protection n Required Required

11

APPENDIX-B: APPENDIX-B: Typical Site Site Layout Layout For Tank Tank Cleaning Cleaning Facility Facility

12

Appendix-C: Appendix-C: Octel Handbook Handbook on Leaded Leaded Gasoline Gasoline Tank Cleaning and Disposal of Sludge

13




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Safe Work Practice On Entry & Cleaning Of Leaded Fuel Storage Tanks Contents Sl #

Topic

Page #

1.0

Introduction

3

2.0

Hazards Of Lead Alkyls

3

3.0

Selection Of Personnel

4

4.0

Respiratory Protection

5

5.0

Protective Clothing

6

6.0

Tank Cleaning

7

7.0

Tank Inspection

10

8.0

Marking Of Tanks

10

9.0

Disposal Of Leaded Sludge

10

APPENDIX-A: APPENDIX-A: Cleaning Cleaning Procedures Procedures And Personal Personal Protectio Protection n Required Required

11

APPENDIX-B: APPENDIX-B: Typical Site Site Layout Layout For Tank Tank Cleaning Cleaning Facility Facility

12

Appendix-C: Appendix-C: Octel Handbook Handbook on Leaded Leaded Gasoline Gasoline Tank Cleaning and Disposal of Sludge

13




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Safe Work Practice On Entry & Cleaning Of Leaded Fuel Storage Tanks 1.0

Introduction

Tetraethyl lead and Tetramethyl lead commonly referred to as TEL and TML are the lead alkyl compounds added in very small quantities to motor gasoline to improve their octane rating. The highly toxic properties of lead alkyl compounds (in their concentrated form used for blending) necessitate strict observance of safety procedures during its handling. Since introduction of lead free gasoline in October 1998, the use of lead alkyls has been greatly reduced. In future, it is expected to be eliminated totally. The precautions may vary somewhat with the nature of the work but are based on the same general principles. The precautions provided in this document are supplementary to the requirements of the relevant work permits applicable to the job. Detailed work practices to cover all aspects of job involving TEL/TML are provided in Octel handbook, available on the HSE website and also attached as an Appendix – C. 2.0

Hazards of Lead Alkyls

Lead Alkyls are highly toxic to the central nervous system (CNS) when accumulated over a period of time. Overall toxic hazard of TEL and TML are similar. It can enter the body by inhalation of vapor, by ingestion of the liquid and absorption of the liquid through the skin. 2.1

Threshold Limit Value-Time Weighted Average Concentration

The maximum permissible time weighted average concentration in air over an eight hour workday, known as TLV-TWA, for TEL is 0.1 mg(lead)/m 3 ( 0.0075 ppm organic lead in air) and for TML is 0.15 mg(lead)/m 3 (0.013 ppm organic lead in air). In situations where both TEL and TML vapor may be present, the lower TLV of 0.1 mg(lead)/m 3 shall be adhered to. Measurement of concentration of organic lead vapors in air can only be made by using a lead-in-air analyzer. For details of the procedure, reference should be made to Octel Handbook. 2.2

Potential of Exposure

Exposure to toxic vapor can occur under the following conditions if adequate protective equipments are not used.




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3.0

-

Leak or spills

-

Handling sludge of leaded gasoline tank

-

Maintenance work in leaded gasoline tank

-

Transferring Transferring of TEL/TML from wagons or drums

Selection of Personnel

It is essential that personnel employed to work involving lead alkyl compounds are physically fit, medically examined, knowledgeable about their job, have a high sense of responsibility and are reliable. Operations/ Maintenance TL of the area shall ensure that minimum number of personnel required to accomplish the job shall be engaged and hazardous operations should be shared equally among the members of a team to prevent the possibility of excessive exposure of any one individual. Exposure records of personnel shall be maintained. 3.1

Medical Check-Up

It is essential that all personnel engaged in or associated with jobs involving lead alkyls are medically supervised to ensure that they are not affected due to any exposure. All personnel associated with TEL/TML jobs shall undergo an initial medical check up and subsequent check-ups twice yearly (or more frequently if warranted by the level of exposure). This facility is available at KNPC Clinic and personnel assigned to jobs involving TEL/TML shall be subjected to initial medical check and subsequent follow up. 3.2

Medical Authorization Certificate

This certificate is issued for a period of six months (or less as explained above) to concerned individuals by the Medical Services Div. to certify that the bearer is medically fit to work on equipment, using appropriate PPE, where potential of exposure to TEL/TML exists. Personnel working on such equipment shall be in possession of a valid medical authorization authorization certificate. 4.0

Respiratory Protection: The equipment required to provide respiratory protection against toxicity of lead vapor is described below. The choice of equipment will depend on conditions under which it is being used.

All personnel personnel required required to use respiratory respiratory protections protections shall shall be trained trained and certified in their use.




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KUWAIT NATIONAL PETROLEUM COMPANY 4.1

4.2

4.3

Cartridge Respirator

a.

Cartridge respirator provides adequate protection in open areas. These are recommended for normal operations on blending plants and for work outside manholes of tanks of TEL/TML or leaded gasoline. They are also suitable for use in emergency situation involving spills in open area.

b.

Cartridge respirators shall never be used, even for inspection purpose, inside a tank or a confined space that has at any time contained leaded gasoline.

c.

In general, the cartridges shall be replaced once every shift/day. The useful life of cartridge can get adversely effected if used in high concentration of lead alkyls, gasoline vapors or moisture and in such a case it shall be immediately replaced.

Air Line Respirators

a.

Continuous flow type (not a demand flow type) air line respirators are recommended for emergency use in case of spills, tank cleaning and fitting operations in confined space where ventilation is poor.

b.

The airflow rates shall Minimum airflow rate to the facemask shall be 120 lit/min. The size of hose for air supply shall be 10 mm ID, 17 m m OD and made of Terylene or Nylon reinforced PVC or wire reinforced PVC.

c.

Air to the respirator shall be supplied by a compressor situated outside and upwind of contaminated area through a suitable filter to remove oil, moisture, dust and shall have CO & CO 2 monitoring system. This filter shall be supplemented by other filter on the wearer’s belt to remove any dust that may have been picked up from the hose. The air intake of the compressor shall be kept clear from exhaust gases of engines and any other source of noxious gases.

Self-Contained Breathing Apparatus

Pressure demand type SCBA provides complete mobility to the wearer and is recommended for emergency use in case of fire or spills. Airline respirator provides the same degree of protection but is less suitable because of the possibility of hose being damaged by fire in addition to restricting the mobility of the wearer. 4.4

Air Supplied Suits

a.

The air-supplied suit is recommended for use during tank cleaning as it provides a high degree of safety and comfort, particularly in hot climate.

b.

The air-supplied suit shall be fabricated form Neoprene-proofed Terylene cloth and tested to meet the severe conditions encountered during tank cleaning. The air to the helmet and suit shall be supplied from a compressor via a regulator at an average flow rate of 10-12 scfm (17-20 m 3/hr). When a vortex tube is being used




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for cooling, the air supply pressure at the valve shall be 80 psig (5.5 bar) vs 10 psig (0.7 bar) when vortex tube is not being used.

5.0

c.

An emergency supply of bottled air shall be available with the suit for escape purpose in case of failure of compressed air supply.

d.

The size of hose for air supply shall be 13 mm ID, 22 mm OD, with outer wall made of PVC, inner wall of minimum 3.2 mm thickness made of polyurethane and terylene fabric reinforcement between inner and outer walls.

Protective Clothing

In addition to respiratory protection, protective clothing is also required for all personnel engaged in the handling of lead alkyl compound. The degree of protection required will vary with the nature of work as described below. In every case, a full set of protective clothing and equipment shall be readily available for use in an emergency. All clothing shall be of white color. 5.1

5.2

Handling Road Tankers

a.

White Cotton overalls, head covering, PVC gloves and shoes shall be used.

b.

Canister respirator shall be donned when removing blank flanges, connecting or disconnecting lines or in case of any emergency in open area.

c.

Before leaving the area, personnel shall remove gloves, respirator and overalls and shall wash their hands thoroughly with soap and water. Gloves shall be kept clean and dry.

d.

If an emergency involving spillage contaminates the clothing, the same shall be burned. The person shall shower himself thoroughly using soap and water before reporting for medical check up.

e.

If any mechanical or design problem results in spillage during unloading, head covering, rubber boots, PVC suit, PVC gloves, PVC sleeves and canister respirator shall be used until the problem is resolved.

Operating Totally Enclosed Blending System

a.

PVC gloves shall be used while handling any equipment.

b.

Before leaving the area, personnel shall wash their hands thoroughly with soap and water. Gloves shall be kept clean and dry.




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c.

5.3

6.0

In case of clothing being contaminated, instructions described in ‘Appendix C’ shall be followed.

Maintenance Jobs

a.

All maintenance personnel assigned to work involving potential or anticipated contact with either liquid, vapor compound or sludge shall be supplied with a complete change of white clothing i.e. socks, undergarment, trouser, shirt and overall. This clothing shall be specifically reserved for use in compound area. In addition to this, canister respirator, head covering, rubber boots, PVC suits or aprons, PVC gloves and PVC sleeves shall be used.

b.

All personnel shall shower thoroughly with soap and water as mentioned earlier before leaving the area.

c.

After use clothing shall be cleaned and laundered.

Tank Cleaning

The cleaning of tanks that contain or have contained leaded gasoline is a hazardous operation due to the presence of flammable and toxic vapors in the tank. The sludge and scale removed from tank is also hazardous because of presence of toxic lead compounds. In order to safely carry out the job of tank cleaning and sludge disposal, it is imperative to comply with the recommended safety requirements. 6.1

Personal Protective Equipment For Tank Cleaning

Recommended personal protective equipment (PPE) for different stages of the job are given in Appendix-A for reference. a. All PPE shall be approved by 3 rd party PPE certifying agencies like INSPEC,SGS or SEI to appropriate international standard. b. The international standards related to the PPE are given below. S.No 1

PPE Respiratory Protection

2 3 4 5

Safety Boots Air supplied suit Gloves Aprons/Coveralls

Standards NIOSH, AIHA/ANSI Z88 series standards, EN 132,136,137, EN 14387 latest version EN 13832:2006 EN 943-1:latest version EN 374-latest version EN 340, 13982,14605 latest versions




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6.2

6.3

c.

Safety boots of natural rubber, Neoprene or PVC having protective toe caps shall be worn.

d.

Gloves proofed with PVC and not more than 25 cm long shall be worn.

e.

An air supplied suit made of Neoprene-proofed Terylene fabric with an integral helmet fed from a compressor through 13 mm bore hose is the most suitable protective wear for use inside a tank. In hot weather, vortex tube air cooler shall be used with these suits to provide comfort to the wearer. Air shall be available at a pressure of 100 psig and @ of 15 sm 3/hr per person. Normal clothing shall not be worn under this protective suit and all men shall change their clothing before commencement and after finishing the work.

f.

A properly equipped and trained person shall at all times be in attendance at the entrance of tank to comply with the safety requirements of vessel entry.

g.

Personnel working outside the tank shall wear Neoprene/PVC boots, Neopreneproofed Terylene suit or Neoprene proofed apron or cotton overalls, PVC gloves and cartridge respirators.

Appointment Of Dresser

a.

One man should be appointed as dresser to help men into their protectives and to wipe down their suits, gloves and boots by soap solution while they stand in the tray (see ‘Appendix C’).

b.

The dresser shall be stationed upwind of the job and not too close to tank manholes. He shall wear a canister respirator, PVC gloves, cotton overalls and Neoprene-proofed Terylene Apron/Overall.

Facilities Required For Tank Cleaning

The following facilities shall be available on site before commencement of work. Recommended layout of these facilities is shown in Appendix-B. a.

Wash Room A wash room with shower (and hot water during winter) with adequate supplies of clean towels, nail brushes and soap shall be provided.

The wash room shall not be used for storing or cleaning contaminated equipment, overalls, etc. b.

Cleaning Room A cleaning room or separate temporary shelter or an enclosed area shall be provided for cleaning of contaminated clothing. It shall be equipped with drums having lid for contaminated clothing, sink for washing dirty clothing and a supply of




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clean rags, scrubbing brushes, kerosene, detergent and soap for cleaning clothes and equipment. c.

Equipment Store A room or shelter shall be available for storing all tools and equipment required for tank cleaning job. This room shall not be used as a rest room or for any other purpose.

d.

Tray A steel or polythene tray about 4 ft. square and 4" deep, in which men can stand on leaving the tank while their suits are being washed down with soap solution, shall be provided. Contaminated water shall be disposed as per Octel Procedure.

e.

Steel Sheet Steel sheets with non slip surface shall be laid on ground at entry/exit manholes to prevent soil contamination and formation of puddles.

f.

Dedicated, Clearly Marked Areas For The Following

1. Clean equipment and tools 2. Equipment to be cleaned 3. Items to be burned Areas where respiratory protection is required shall be cordoned by rope and provided with notices. 6.4 Hoses

a.

Selection of right type of hose for air supplied suit or respiratory protective is of importance to ensure complete protection. Type of hose recommended for this operation is mentioned in Appendix C.

b.

Hose shall be checked daily for physical deterioration and discarded on any visible sign.

c.

Hose due to their immersion in sludge can pick up lead. After every 100 hours of use, these hoses shall be checked to see whether the lead pick up is sufficient to contaminate the air passing through the hose. The procedure for this test is described in Octel handbook. If lead content of air is below TLV limit the hose remains suitable for use, otherwise it shall be discarded.

d.

On completion of a tank cleaning operation both ends of the hose shall be capped and then the hose shall be wiped with a kerosene damped rag and washed with water containing detergent. After examining for defects, good hoses shall be dried and stored with end caps still in place for subsequent use.




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KUWAIT NATIONAL PETROLEUM COMPANY 6.5 Ventilation

Confined space entry procedure shall be followed when preparing a tank for safe entry for cleaning or inspection. Sensors used in flammable gas detectors are rapidly poisoned by presence of lead in the gasoline vapors and start giving wrong readings. To ensure accurate detection of leaded flammable vapors, a proper filter designed for lead compounds shall be used on the sampling line. Ventilation of fixed roof or floating roof tank can be achieved by using an air blower or air extractor. Continuous ventilation shall be maintained throughout the tank cleaning operation. 7.0 Tank Inspection

After a tank has been cleaned and de-sludged, sufficient organic lead compound is still present on walls and floors of the tank to produce a toxic environment and hence necessitate use of personnel protective. Personnel entry into the tank for inspections is normally for short duration and air supplied respirator, cotton overalls and PVC gloves are considered as adequate for protection. 8.0 Marking Of Tanks

All tanks, which presently are in leaded product service or had been in similar service in the past shall have the following notice displayed adjacent to all manholes: THIS TANK HAS CONTAINED LEADED GASOLINE. IT MUST NOT BE ENTERED WITHOUT COMPLYING WITH THE PRESCRIBED REGULATIONS. 9.0 Disposal Of Leaded Sludge

Sludge of leaded gasoline tank shall be disposed by the method selected and approved by the company as recommended by Octel. 10.0 Declassification of gasoline tanks previously used for leaded service

The Institute of Petroleum guidance on the Declassification of gasoline tanks previously used for leaded service shall be utilized for this activity.




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KUWAIT NATIONAL PETROLEUM COMPANY APPENDIX-A: CLEANING PROCEDURES AND PROTECTION REQUIRED OPERATION

PROTECTION REQUIRED

REMARKS

-

This stage includes floating off residual product with water

-

-

1. Empty gasoline from tank 2. Assemble and check all equipment 3. Disconnect and blank off delivery and suction lines

PVC gloves

-

Air-supplied respirator or canister respirator, PVC gloves

No respiratory equipment is required until the joint is broken

5. Fit ventilation equipment

-

-

6. Test ventilated tanks with explosimeter

Air-supplied respirator. Canister respirator suitable if the tank is not entered

Continue ventilation at all times

7. Fit sludge pump-suction in tank at low point

Full protection*

4. Open manholes

8. Open clean-outdoors (if fitted)

9. Hose sludge towards sludge pump suction, but do not enter tank 10. Enter tank if necessary and continue cleaning with hoses, shovels, etc.

As 3 above, then airsupplied or canister respirator in the last stage Air-supplied respirator. Canister respirator may be used if the doors are on the windward side of the tank Full protection*

-

-

Hosing may be omitted, especially where water supply limited, or disposal difficult Continue ventilation at all times.

Although the tank may look clean, toxic vapour is 11. Inspect Full protection* present for some time even with good ventilation 12. Carry out repairs as Continuous ventilation is Full protection clothing necessary necessary *"Full protection" means: PVC gloves, rubber or Neoprene or PVC boots and Airsupplied suit and helmet, (with vortex cooler in hot climates) or Neoprene-proofed overalls, plus air-supplied respirator and head protection.




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KUWAIT NATIONAL PETROLEUM COMPANY APPENDIX-B: TYPICAL SITE LAYOUT FOR TANK CLEANING FACILITY




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KUWAIT NATIONAL PETROLEUM COMPANY APPENDIX-C:




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Regulation Safe Work Practice KNPC

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