INDUSTRIAL

CONTINUOUS PROCESS IMPROVEMENT

AND
SAFETY

SPILL CLEAN UP

03/11/16

BILAL MASOOD

PRELIMINARY -- PAINT INDUSTRY

HAZOP HAZAN - HAZID

STUDY
CONDUCTED
BY

BILAL MASOOD

VOLUME -1
EDITION-1

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BILAL MASOOD

HAZID STUDY

PRELIMINARY -- PAINT INDUSTRY

HAZID STUDY
STUDY
CONDUCTED
BY

BILAL MASOOD

03/11/16

BILAL MASOOD

 PRIMILIARY HAZOP/RISK STUDY

MACHINES

MATERIALS

PRODUCTS

BUILDING

HUMAN

WASTE

RAW MATERIALS

NITROCELLOUSE
WARE HOUSE

EQUIPMENT

OTHER PRODUCTS

LEVEL OF RISK

HIGH
MEDIUM
LOW
VERY LOW
NEGLECTED
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OTHER
INDUSTRIAL
UNITS
4

HAZID STUDY

RISK

INDUSTRY PATHS/PASSAGES
SIGNS

CHAPTERS-A

MATERIALS
BUILDING
CONTROL TECHNIQUES

SPECIAL -CHAPTERS-Z

QUALITY
LAB (GLP)
PRODUCTION
SUPPLY CHAIN
LEAN
DECISION TOOLS
PLANNING TOOLS
GMP
ANALYSIS TOOLS
WARE HOUSE
MANAGEMENT

PPE-HUMAN
WASTE

SAFETY ENGINEER

EQUIPMENT/TOOLS/
CONTAINERS

HAZOP STUDY
HAZAN STUDY

MACHINES

CHAPTERS-F

HAZAN STUDY

CHAPTERS-D

CLEANING
OTHER-SIGNS
TRANSPORTATION

LOCOMOTION MANAGEMENT

SAFETY DATA SHEETS

OFFICE MANAGEMENT

AWARENESS

BIOLOGICAL SAFETY

LABELING/CODING

WORKERS BETTERMENT

ADVANCEMENT
MEDICAL/FIRST AID
UTILITIES
MANAGEMENT

EXTERNAL CONDITIONS
OTHER INDUSTRIAL UNITS

PESTS & RODENTS

ENVIROMENT
COMMUNICATION
INDUSTRIAL SURVEY

TOPICS & CHAPTERS

03/11/16

SPILL CLEANING

EXTERNAL WORK

DISPLAY BOARDS
STORAGE & INVENTORY
FERNITURE

FIRE SAFETY
HAZMAT

DISPATCH & FILLING/PACK

Nitro Cellouse
SAFETY

CHECK SHEETS
SOPS & QUALITY
SHIFT CHANGE HAZIDS

CHAPTERS-R
BILAL MASOOD

The purpose of procedure is to ensure any chemical spills are cleaned up appropriately.
There are various steps that laboratory personnel can take in the event of a laboratory spill.
The laboratory worker may be able to respond to a small contained lab spill. Laboratory
workers should never put themselves in harms way. If there is any doubt about the safety of
the individual in the lab

What Denes a Minor Spill:
An amount that is safe to clean up
The spill is easily contained from drains, igniUon sources, and incompaUble chemicals
The spill in not immediately dangerous to life or health (IDLH)
There is no likelihood of re or explosion
Proper Personal ProtecUve Equipment (PPE) is available and person is t tested and
trained in use
Appropriate spills kit is available and person has been trained how to use

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Procedure
Once the risk of injuries has been controlled, the spill may be cleaned up and the area
decontaminated using the following general procedures:
1) NoUfy all personnel and the supervisor in the vicinity of the spill, of any ammable,
highly toxic or volaUle material is spilled. Evacuate and post warnings in the area if
necessary.
2) If clothing has become contaminated, remove and enter emergency shower, if eyes have
been aected, ush eyes for 15 minutes.
NOTE: BE SURE CHEMICAL IS NOT WATER REACTIVE.

before responding to any spill the following informaUon must be obtained: Name of the
chemical(s) involved.
Approximate quanUty.
Hazards of the chemical (review MSDS if available):
o Flammability: ash point; vapour pressure o Toxicity TLV
o Corrosiveness pH

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Never proceed to clean up a spill if you do not know the hazards associated with the chemical or if
you are unsure of how to clean up the spill.

1. Alert people in the area.
2. Determine what chemicals were involved in the spill.
3. If someone has been splashed with chemicals, immediately escort them to the emergency
shower or eyewash. Call 1122 or seek medical agenUon immediately.
4. Choose appropriate personal protecUve equipment (PPE) to wear including safety goggles, gloves
prior to cleanup. Access to Material Safety Data Sheets (MSDS) should be available in your work
area or by asking your immediate supervisor.
5. Prevent the spreading of spill over a large area. Use a commercial spill kit or absorbent material
from your spill kit to absorb spilled materials. If the chemical is moving towards water or soil, place
an absorbent pad around area to prevent the chemical from entering the soil or water source. If
the chemical does enter the soil or a water source, please contact emergency immediately.
6. Blanket the spill with absorbent material, such as MagicSorb, vermiculite or absorbent pads. The
use of a neutralizing agent is not recommended within the building as toxic vapors may be
emi:ed as a result of the chemical reac;on. Sweep up the absorbent using a scoop, shovel, or
small dustpan and broom. If there is broken glass, use a tong to pick up or the scoop to prevent
injury or exposure to the chemical involved.
7. Place the saturated absorbent waste into a hazardous waste container.
8. Label the hazardous waste container with a hazardous waste tag
9. Clean the chemical residue with water.
10. Remove PPE and wash your hands with soap and water.
11. Replenish your spill kit supplies, so the kit is ready when you need it.

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10


Procedures for a Complex or Major Spill
Ensure you move to a safe locaUon
Alert sta in area; contact Supervisor/Principal InvesUgator
Provide rescue or rst-aid only if you are safe to do so
Pull re alarm, or call Security/Emergency Response
Be prepared to provide details of chemical spill (locaUon, amount, Material Safety
Data Sheet (MSDS) and any other potenUal hazards/chemical mixtures)

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11

Mercury spill
1) Report the spill to a supervisor; if necessary
2) Evacuate all personnel from area if spill is large, or room is small and venUlaUon
is poor.
3) Wear appropriate personal protecUve equipment such as lab coat, rubber, latex
or vinyl gloves, plasUc boot protectors, splash goggles and half-mask respirator
with approved cartridge for mercury vapours
4) VenUlate area as much as possible; i.e. open all windows.
5) Mark o spill area with signs, barriers or tape.
6) Pool mercury using sU paper or plasUc sheet to carefully manoeuvre beads of
mercury into one large pool.
7) Shake o any mercury that clings to paper or plasUc into a wide-mouth container
before being transferred with a funnel into a small, clean container.
8) Pick up mercury using a glass pipege with a rubber bulb OR a glass lter ask equipped
with a trap and a vacuum source such as a large rubber bulb, water
aspirator, vacuum tap or vacuum pump.
9) Transfer liquid mercury to glass (preferable) or plasUc bogle of the smallest size
possible equipped with a Ught ing lid. Label 'Waste Mercury".
10) Decontaminate spill area by using one of the following methods:

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12

a. Dust area of spill with sulfur powder, then sweep mercury/sulfur mixture into
wide-mouth jar equipped with Ught ing lid.
OR
b. Use zinc pieces (pre-rinsed in dilute hydrochloric acid) to act as magnets to pick up
mercury droplets, then place zinc/mercury pieces into wide-mouth jar equipped with Ught
ing lid. Label the wide-mouth jar: "Mercury/Clean-up Materials.
11) The nal clean-up steps include:
a. Cracks - spread sulphur or spray MERCONVAP soluUon into cracks and
leave as a cover to inhibit evaporaUon of any mercury that is not visible or
accessible.
b. Remove all personal protecUve equipment before leaving room
decontaminate or dispose of as Waste Mercury Materials.
c. Place all labelled mercury containers into a solid container and label
appropriately - i.e. 'Waste Mercury"' or "Mercury Clean-up Materials.

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13

Flammable Solvents
Note: Never agempt to clean up a solvent spill if an igniUon source is present
1) Apply solvent absorbent (Spill X-S, Solusorb or equivalent product) from the perimeter inward,
covering the total spill area.
2) Mix thoroughly with plasUc scoops unUl material is dry and free owing, and no evidence of free
liquid remains.
3) Transfer the absorbed solvent to an appropriate disposal container that is not soluble in the solvent,
and seal the container.

Acids
(except hydrouoric acid and perchloric acid
1 Apply acid neutralizer (Spill X-A, Neutrasorb or equivalent product) from the perimeter of the spill,
inward.
2) Carefully mix with brushes and scoops; if necessary, add more neutralizer to any free acid.
3) When foaming subsides, check pH of a homogeneous sample of the mixture.
4) Test pH with pH
5) If pH is not between 4 and 10, add more neutralizer.
6) When the acid has been suciently neutralized, pick up treated material with
scoops and transfer to a disposal container.
7) Seal container appropriately, and label.
8) Decontaminate and wash spill site surfaces with soapy water and wet sponge.

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14

CausZcs
1) Apply neutralizer for causUcs (Spill X-C, Neutracit-2 or equivalent product) from the
perimeter of the spill, inward.
2) Carefully mix with brushes and scoops; if necessary, add more neutralizer to any free
base.
3) When foaming subsides, check pH of a homogeneous sample of the mixture.
4) Test pH with pH
5) If pH is not between 4 and 10, add more neutralizer.
6) When the causUc has been suciently neutralized, pick up treated material with
scoops and transfer to a disposal bag container.
7) Seal container appropriately, and label.
8) Decontaminate and wash spill area surfaces with water and wet sponge.

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15

SPILL CLEANING KIT

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16

Spill Clean-Up Sorbent Pillows

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17

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18

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19

PRESENT INDUSTRIAL
CONDITION

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20

LEVEL
HIGH
MEDIUM
LOW
NEGLECTED

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21

RISK

LEVEL

REMARKS

HIGH
MEDIUM

OCCURANCE

HIGH
HIGH
LOW
NEGLECTED
HIGH

BILAL MASOOD
03/11/16

HIGH
NEGLECTED
HIGH

HIGH
NEGLECTED
HIGH

HIGH

HIGH
NEGLECTED
HIGH

HIGH

22

ACTION

NOTES

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23

NOTES

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24