OKI PULP & PAPER MILL Project No.

P-OkiPL1
PROJECT
[OKIPL1] Document No. P-OkiPL1-100-01-FRM-XXX
Revision 00
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Handling of Corrosive Substance
Issue Date February 10, 2016

HANDLING OF CORROSIVE SUBSTANCES

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[OKIPL1] Document No. P-OkiPL1-100-01-FRM-XXX
Revision 00
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Handling of Corrosive Substance
Issue Date February 10, 2016

CONTENTS

1. SCOPE

2. DEFINITIONS

3. PLANT & APPARATUS IDENTIFICATIONS

4. DANGERS

5. HEALTH AND SAFETY

6. CORROSIVE SUBSTANCES STORE

7. OPERATION WITH CORROSIVE ACIDS

8. HANDLING OF CORROSIVE ACIDS

9. HANDLING CAUSTIC ALKALI

10. HANDLING SODIUM HYPOCHLORITE

11. HANDLING CONCENTRATED AMMONIA SOLUTION

12. HANDLING HYDRAZINE

13. HANDLING TRISODIUM PHOSPHATE

14. WORK ON WATER TREATMENT PLANT AND CHEMICAL DOSING EQUIPMENT

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Handling of Corrosive Substance
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1. SCOPE

The purpose of this Code of Practice is to give guidance on the procedures

for the safe handling of corrosive substances. These substances are
represented by chemicals which are used in a number of systems namely
the Water Treatment Plant, the Power Train Chemical Dosing Plant and
CCCW Plant. The chemicals used are caustic soda, sulphuric acid, ammonia,
hydrazine and trisodium phosphate. Chemicals will be delivered, stored and
handled in several areas of the power station and used in specifically
designed processes. The guidance meets the requirements of the UK Health
and Safety at Work etc.. Act 1974 and the COSHH Regulations.

2. DEFINITIONS

Terms printed in bold type are as defined in the SZC Safety Rules.

3. PLANT AND APPARATUS IDENTIFICATION

Plant and Apparatus on which work or testing is to be carried out must be

readily identifiable or have fixed to it a means of identification which will
remain effective throughout the course of work or testing.

4. DANGERS

The corrosive chemicals used in the various processes can give rise the
Danger to personnel if not handled correctly. Chemicals can represent a
health hazard. They can be absorbed through the skin, enter the eyes or are
inhaled into the lungs and may cause permanent damage to some organs.
The receipt, handling, spillage and use of these chemicals shall be in
accordance with Approved local procedures and individual plant
manufacturers operation and maintenance manuals. Chemicals can be
delivered in bulk or delivered in drums, carboys or similar containers. Bulk
deliveries can give rise to Danger if two incompatible chemicals are mixed
resulting the generation of heat and the possibility of an explosion
developing. Similarly the dilution of acids can lead to a risk of Danger to
personnel if maloperation allows water to be added to concentrated acid.

5. HEALTH AND SAFETY

a) First Aid

i) First aid measures should be laid down as part of a local

Approved procedure for each of the chemicals stored.

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ii) At each bulk filling point at strategic positions around the Plant
both internally and externally there shall be displayed the
locations and telephone numbers of first aid and emergency
services.

b) Personal Safety

i) Personal emergency showers and eye wash facilities shall be

provided in the WTP and adjacent to storage vessel discharge
points. The shower shall operate automatically with the entry
of a person under the shower and initiate an alarm which shall
operate locally both audibly and visually and be repeated in the
Central Control Room. Showers shall be clearly indicated as
emergency showers are where necessary be protected from
frost.

ii) Hazard assessment information together with the prevention

and control measures relating to exposure shall be produced
for each corrosive chemical stored, used and identified as a
substance hazardous to health in accordance with The UK
Control of Substances Hazardous to Health (COSHH)
Regulations. Reference should be made to H.S.E. Guidance
Note EH40 for Occupational Exposure Limits.

iii) All personnel shall comply with the hazard assessment

information prevention and control measures provided for the
identified corrosive substances. In particular they shall:-

Wear, in the proper manner the Personal Protective Equipment

provided.

Remove Personal Protective Equipment which could cause

contamination and pose a risk to health before eating, drinking
or smoking.

Practise a high standard of personal hygiene and make proper

use of the facilities provided for washing, showering eating and
drinking.

Not smoke, drink or eat in the work area.

Report immediately any defective Personal Protective

Equipment or deficiency in maintaining the laid down
prevention and control measures.

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iv) Information, instruction and training should be given to

personnel who may be exposed to substances hazardous to
health.

c) Spillage

i) Local Approved Safety Instructions procedures shall be laid

down for dealing with both minor and major spillages. The
procedures shall be such that as to minimise the risk of danger
to personnel and the pollution of the environment. If pollutants
are known to have been discharged from the site into
Controlled Waters the appropriate authorities must be
informed. Reporting of incidents with potential risk is the
responsibility of the Site Manager Nominee in accordance with
the Site Environmental Management Plan.

ii) Adequate provision must be made for hosepipe facilities to deal

with spillages with sufficient water supplies available at each
chemical supply point for washdown and emergency use.
These facilities must be adequate to achieve rapid and safe
dilution of the spillage. Consideration should be given to having
sodium carbonate ready available for neutralising diluted acids.

6. CORROSIVE SUBSTANCES STORE

(a) Corrosive substances shall be stored under the correct category as

laid out under the UK Health and Safety Commission "Information
Approved for the Classification, Packaging and Labelling of Dangerous
Substances", as revised or reissued from time to time.

(b) Corrosive substances classified under different categories shall not be

stored in close proximity to each other, all corrosive substances shall
be distinctly labelled.

(c) Corrosive substance containers shall be neatly stacked and easily

accessible. Stacks shall not be made high to prevent damage to lower
containers by compression.

(d) Damaged containers shall not be stored unless the corrosive

substance is repacked.

(e) Lighting and ventilation equipment shall be maintained in good order.

(f) The store shall be vacuum cleaned when necessary to reduce toxic
dust inhalation. Removal of spilled powder by brushing is prohibited.
Debris collected shall be carefully and properly disposed of.

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(g) Flames, smoking and sparks shall be prohibited in the vicinity of

corrosive substances.

7. OPERATIONS WITH CORROSIVE SUBSTANCES

(a) All areas where work of a chemical nature is being carried out shall
have their areas barriered off and the appropriate warning notices
prominently displayed.

(b) Unauthorised entry into Barrie red off areas shall be prohibited.

(c) Containers containing corrosive substances shall not be left in the

work area. Empty containers must be thoroughly rinsed with water
before disposing. Empty containers shall not be left at the work area.

(d) All chemical operations shall be carried out under the Personal
Supervision of a person with technical knowledge and experience of
such operations.

8. HANDLING CORROSIVE ACIDS

(a) Concentrated sulphuric acid is used in the WTP. Sulphuric acid is

highly corrosive and will cause severe burns if allowed to come into
contact with the eyes or the skin. Sodium bicarbonate, an antidote
must be available in case of an accident and running water must be
available when corrosive acids are handled.

(b) Concentrated acids if diluted by water will generate excessive heat.

Water shall never be poured into acid at any time as the heat
generated may spatter the mixture or cause a failure of the acid
container.

(c) In case of an accident :

(i) All contaminated clothing should be removed.

(ii) Neutralise with the antidote except for eye contact and rinse
the affected areas with plenty of water for at least 10 minutes.
Effective flushing of the eyes is required and this treatment
may require help form others to open the eyeducts. Medical
attention should be summoned immediately.

(d) In case of spillage :

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(i) Ventilate and isolate the area. Spillage of concentrated acids

generates irritating and harmful fumes. Personal Protective
Equipment must be worn whilst undertaking contingency tasks.

(ii) Neutralise the concentrated acid in a controlled manner as to

prevent the generation of heat using solid sodium bicarbonate
or a soda ash - sodium hydroxide 50/50 mixture.

(iii) Carefully scoop up the neutralised mixture and sluice the

mixture down the drain with copious amounts of running water.

9. HANDLING CAUSTIC ALKALINE

(a) Caustic soda (sodium hydroxide) is used in demineralisation plants for

regeneration of Ion exchange resins and in effluent treatment plant
for neutralisation of effluent.

(b) Both caustic soda and caustic potash are highly corrosive and will
cause severe burns if allowed to come into contact with skin or eyes.

(c) An antidote such as dilute acetic acid must be available in case of

accident. Running water must be available when caustic alkalis are
handled.

(d) In case of accidents :

(i) Neutralise with antidote except for eye contact and rinse the
affected areas with plenty of water for at least 10 minutes.
Effective flushing of the eyes is required and this treatment
may require help from others to open the eyelids. Medical
attention should be summoned immediately.

(e) In case of spillage :

(i) Ventilate and isolate the area. Personal Protective Equipment

must be worn when undertaking contingency tasks.

(ii) Neutralise the concentrated alkali in a controlled manner as to

prevent the generation of heat. In the case of solids apply
plenty of dry sand and mix. Neutralise with diluted hydrochloric
acid, testing with PH paper or PH meter allowing time for the
alkali to

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react before testing. Carefully add the mixture to a large

volume of water which will dissolve in it. Dilute with copious
amounts of running water until the operation is complete.

Dispose of the sand in normal refuse.

In the case of liquids :

Neutralise caustic liquid with diluted hydrochloric acid.

Apply copious amounts of water.
Sluice resulting solution to drain continuing dilution.

10. HANDLING SODIUM HYPOCHLORITE

(a) Concentrated sodium hypochlorite solutions (approximately 14% Cl 2)

can be used in sewage treatment plant as disinfecting agent.

(b) Concentrated sodium hypochlorite solution (approximately 14% Cl 2) is

very corrosive. Contact with the eyes and skin must be avoided.
Personal Protective Equipment must be worn whilst handling sodium
hypochlorite.

(c) Toxic chlorine gas may be generated when the concentrated solution
is heated or strongly acidified. Therefore, concentrated sodium
hypochlorite solution should be kept in a cool, sheltered and well
ventilated place away from direct sunlight or heat. It must not be
allowed to come into contact with strong acids.

(d) An antidote such as dilute acetic acid must be available when sodium
hypochlorite is handled in case of accident.

(e) In case of accident :

(i) Remove all contaminated clothing.

(ii) Neutralise with antidote except for eye contact and wash
affected areas thoroughly with copious amounts of water.

(f) In case of spillage :

(i) Ventilate and isolate the area. Personal Protective Equipment

must be worn whilst undertaking contingency tasks.

(ii) Sluice the spilled sodium hypochlorite solution with copious

amounts of water to the waste drain. If a considerable amount
of chlorine is evolved, sprinkle sodium sulphate and sodium

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bicarbonate powder over the spillage to suppress further

gaseous evolution.

11. HANDLING CONCENTRATED AMMONIA SOLUTION

(a) Ammonia is used for LP chemical dosing in condensate and feed

system.

(b) Concentrated ammonia solution gives off irritating fumes. It will also
cause severe burns if allowed to come into contact with the skin or
eyes. Personal Protective Equipment must be worn whilst handling
ammonia.

(c) In case of accident :

(i) Remove all contaminated clothing.

(ii) Neutralise with antidote except for eye contact and rinse the
affected areas with copious amounts of water for at least 10
minutes. Medical attention should be summoned immediately.

(d) In case of spillage :

(i) Ventilate and isolate the area, Personal Protective Equipment

must be worn whilst undertaking contingency tasks.

(ii) Neutralise the concentrated ammonia in a controlled manner

as to prevent the generation of heat. Neutralise the ammonia
with dilute hydrochloric acid and sluice the resulting solution to
waste diluting continuously with copious amounts of water.

12. HANDLING HYDRAZINE

(a) Hydrazine is used on LP chemical dosing on condensate and feed

systems.

(b) Hydrazine is toxic and is a carcinogen. It fumes when exposed to air

and is a strong irritant. The liquid is corrosive and flammable and may
cause burns if allowed in contact with the skin. It can also be
absorbed through the skin to cause mild or severe poisoning. The
possibility of damage to the kidney and liver organs can occur later.
Direct skin contact must be avoided under all circumstances.

Personal Protective Equipment must be worn whilst handling

hydrazine.

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(c) An antidote such as dilute acetic acid must be available when

handling hydrazine In case of accident.

(d) In case of accident :

(i) Remove all contaminated clothing.

(ii) Neutralise with antidote except for eye contact and wash
affected areas thoroughly with soap and copious amounts of
water. Medical attention should be summoned immediately.

(e) In case of spillage :

(i) Ventilate and isolate the area. Personal Protective Equipment

must be worn whilst undertaking contingency tasks.

(ii) Cover the spillage with sand and shovel the resulting mix into
suitable receptacles e.g. polythene buckets with lids. Carefully
add an excess of dilute hydrochloric acid or dilute sulphuric
acid.

(iii) Stir the mix well and allow to stand for 24 hours, after 24 hours
run the acid extract to waste by decanting using copious
amounts

of running water. Wash the sand afterwards with cold water and
treat it in normal refuse.

13. HANDLING TRISODIUM PHOSPHATE

(a) Trisodium phosphate is an alkali and used as an additive for Boiler

and HRSG water conditioning and occasional dosing of the CCCW
system.

(b) Trisodium phosphate is toxic in its acute effects, causes irritation to

the eyes, skin and digestive system. Its liquid acts as degreasing
agent to the skin. Significant acute inhalation exposure may result in
lung damage. It is non-combustible but may generic toxic fumes in a
fire. Personal Protective Equipment must be worn whilst handling
Trisodium Phosphate.

c) In case of accident:

i) Skin Contact

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Brush off excess material. Remove all contaminated clothing.

Rinse the affected areas with copious amounts of water. Seek
medical attention if irritation persists.

ii) Eye Contact

Irrigate eye thoroughly with water for at least 10 minutes.

Effective irrigation of the eyes is required and this treatment
may require help from others to open the eyelids. Medical
attention should be summoned immediately.

iii) Ingestion

Amounts ingested due industrial handling are not likely to

adverse cause injury. Excessive doses may be harmful. If this
occurs wash out mouth with water and seek medical attention.
Do not induce vomiting.

d) In case of spillage:

Sweep spilt produce aside to safe place. Flush the spillage to

approved drain with copious amounts of water. Personal Protective
Equipment must be worn when dealing with contingency tasks.

e) In case of fire:

Although non combustible may generate toxic fumes in a fire.

Personal Protective Equipment and Breathing Apparatus should be
worn. For a small fire apply CO2, dry powder, alcohol resistant foam or
water spray. For a large fire apply alcohol resistant foam or water
spray.

14. WORK ON WATER TREATMENT PLANT AND CHEMICAL DOSING

EQUIPMENT

The work shall be carried out in accordance with ALSTOM Safety Rules.

When work has to be carried out on the Plant, Safety from the System
as required by the SZC Safety Rules, shall be determined by the appropriate
Safety Controller. Valves shall be Isolated and Locked. Plant to be
worked on shall be Isolated, cleaned out and made chemically safe. When
the Safety Controller considers it necessary he shall obtain advice from
the appropriate Selected Person on any additional precautions which may be
necessary in respect of particular hazards.

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Entry into storage tanks or ion exchange resin vessels shall comply with the
requirements of the SZC Rules and relevant Safety Codes of Practice
(SRCOP).

Maintenance personnel shall wear Approved Personnel Protective

Equipment while dismantling parts which have contained, or may still
contain, entrapped hazardous or corrosive substances and that such
Personnel Protective Equipment is maintained until the parts have been
cleaned and are free from unacceptable chemical contamination.

Plant which have contained chemicals should be thoroughly rinsed and

proved free from hazardous chemicals before being taken to the workshop
for maintenance.

After cleansing, parts which contain or make contact with concentrated acid
should be thoroughly dried and kept dry prior to being relocated in the Plant.

All maintenance work, particularly chemical removal and plant cleaning,

shall be carried out so as to prevent environmental pollution in accordance
with the Site Environmental Management Plan.

Before returning the Plant to service after maintenance an inspection shall

be carried out to ensure that the plant is in a safe condition. The recharging
of chemical pipelines, tanks etc. shall be carried out under the Personal
Supervision of a person with extensive experience of such Plant
Systems.

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