Ammonia Storage TerminalsSafety Program

This program is designed to assist terminal personnel in developingtheir own program and to show how the plans for each individualterminal can be adapted for maximum benefit.

C. Clay HalePEDCo., Cincinnati, Oh.

W.H. LichtenbergCominco American, Borger, Tex.

INTRODUCTION

The supervisors of the large refrigeratedammonia storage terminals must accept a con-siderable burden of responsibility for theoverall safety for the Owners. This respons-ibility includes not only the protection ofthe company property, but also the protectionof the people working and living in the area.To carry out this assignment properly involvespreplanning, personnel training, and makingsure the facilities are in good working orderto avoid accidents. Then if accidents dooccur, to limit the damage by being preparedwith the plan and facilities to react withoutdelay.

In addition to continuous upgrading of theoperator training, these plans should includeperiodic inspection of all critical items ofequipment. The plans for handling emergenciesshould include all available help from thelocal community and government officials tosupplement company manpower. Possibly helpfrom industrial neighbors may be availableon a cooperative basis. Finally, adequatefirst aid and medical facilities should beavailable in case of personnel injury. Theavailable medical personnel should be readywith supplies to carry out this treatmentwithout delay. Prompt action in the case ofeither an emergency spill or an injury cansignificantly reduce the extent of the damage.

Planning can make a significant difference ifthe plans are implemented with training andadequate facilities. If a real emergency oc-curs and the personnel available do not havea well prepared written plan, the resultscould be much more serious than would haveoccurred if the plan was available.

This safety program is designed as a generalguide to assist terminal personnel in develop-ing their own program. The program has beenbroken down into eight sections (see Table ofContents, Sections I through VIII). Each ofthese sections are interrelated but emphasizea separate phase of the work.

All sections are essential in the overallsafety of the terminal.

A review of the local situation will usuallyindicate how the plans for each individualterminal can be adapted for maximum benefit.

SUMMARY

I. EMERGENCY CONDITIONS defines a seriesof typical problems that may occur.By defining and describing these poten-tial hazard conditions, the plan toreact to these emergencies can bedeveloped.

0149-3701 -80-3892 $01.00 © 1980American Institute of Chemical Engineers

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11• ORGANIZATION FOR HANDLING EMERGENCIESoffers the typical manpower sourceswhich may be available to supplementthe terminal staff.

III. HAZARDS AND THEIR CONTROL describesin detail the technical aspects ofthe hazards in handling ammonia.

IV. FIRST AID AND MEDICAL TREATMENT FORAMMONIA presents a typical procedurewhich has been developed by the indus-try operators.

V. SAFETY TRAINING includes typical sub-jects for the weekly safety meetingsfor operators and maintenance employeesin the terminal. Additional traininglists are also presented for transpor-tation personnel (truck drives orswitchengine operators) that servicethe terminal. Programs for localauthorities and groups that may beavailable during an emergency are pre-sented for consideration. The programlists are intended as a guide to startthe training programs. As the trainingprogresses, additional items for discus-sion will arise and can be included.

VI. ACCIDENT PREVENTION describes a seriesof recommendations such as periodicinspections to avoid problems. Thisincludes preventative maintenance andtesting.

VII. PROPERTIES OF ANHYDROUS AMMONIA pre-sents standard data for ammonia inthe terminal. This should be avail-able to all personnel.

VIII. The final REFERENCE section listsavailable publications which are avail-able and can be purchased to supplementor replace sections of this program.

I. EMERGENCY CONDITIONS

A major emergency will exist wheneveryou have an ammonia spill or an uncon-trollable release of ammonia vapor.The condition must exist for at leastfive minutes; otherwise, any emergencyprocedure could not be implemented intime to do any good.

An emergency condition usually resultsfrom an equipment failure, such as aruptured hose, ruptured vessel, rup-tured pipeline, or a blown pump seal;

or carelessness on the part of a worker,i.e. mispositioned valve.

The basic procedure consists of isolat-ing the discharge area as rapidly aspossible to minimize the amount of pro-duct being discharged. This will con-sist of actuating some or all emergencystop buttons located either in the con-trol room, in the scale house, in thepump area, or load-out area. Any man-ual valves, which reduce the amount ofammonia being released that can bereached without endangering personnel,should be closed as quickly as possible.If there is any possible danger, theproper protective breathing apparatusand protective clothing suit must beput on before going into the dischargearea. Until the overall situation canbe evaluated, try to get upwind fromthe spill area after warning everyother person on the premises.

Call emergency telephone numbers suchas the FIRE DEPARTMENT and POLICE -which numbers will have been previouslydetermined and posted by the terminalmanager and give the followinginformation:

Name and location of facilityNature and extent of emergencyWind direction.

In summary, the definition of an ammoniaemergency is any accident or incidentso serious that employee personnel can-not keep the situation under control,thereby endangering personnel," surround-ing neighbors, and highway traffic.The following pertains to an ammoniaemergency :

A. The first step is to always takewhatever precautions are necessaryto avoid a major crisis:

1. Shut down terminal loadingequipment using emergency stopbuttons in control room orpump switches in truck andtank car scale area.

2. Get upwind of discharge andwarn other personnel in area.You should check the windevery day.

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B. Use the proper safety equipmentso as to minimize or avoid injury:

1. Use self-contained breathingapparatus.

2. Full protective clothing madeof rubber or other materialimpervious to ammonia.

3. An industrial gas mask withfull-face mask and NH3 (green)canister. This type does notcontain its own oxygen supplyand, therefore, it is limitedto use for brief periods notexceeding 15 minutes in con-centrations up to 3 percent.

4. If wet suit and self-containedbreathing apparatus is used,a second man should be in asuit too with a life line con-nected to the first man as abackup.

5. Proceed with extreme cautioninto problem area, upwind ifpossible, making repairs orclosing off valves, etc., asquickly as possible and leavethe area. If alarm soundsinside the suit while makingrepairs, do not continue thework even though the job maybe near completion. Whenalarm sounds, leave the con-taminated area at once.

C. If anyone is injured, be sure tomove them to a safe place:

1. Move injured upwind of spilland give proper first aid.

2. Notify ambulance, doctor,and hospital.

D. Depending on the type and extentof injury, use first-aid proceduresas described previously.

E. Shut down system immediately.Close hand valves downstream ofprobable problem area. Block off,if possible, applicable section ofsystem where leak is present toreduce danger of escaping ammoniaand loss of product. Dependingon location of leak, use one or

two fire hoses by playing a waterspray or fog on escaping ammoniato reduce the amount of vapor re-leased to the atmosphere. If aleak occurs within the dike area,check to be sure that the gatevalve to the river or drainage sys-tem is closed and will contain anyliquid ammonia.

F. Notify proper people in the follow-ing order:

1. Terminal manager

2. Operators

3. Fire department - to help waterdown any vapors, to assist per-sonnel in getting into areasfor the purpose of closingvalves, or to get injured per-sons out.

4. Law enforcement officials:

a_. Localb. Sheriff£. StatecL US Coast Guard (where

applicable)

To help control motorists onhighways around terminal andto help alert residents andevacuate if necessary. Alertto possibility of ammoniaentering water system.

5. Doctor

6. Ambulance

7. Hospital (Numbers 5, 6, and 7above are to be alerted if any-one is injured. They shouldbe made aware of the type ofemergency and ask them tostand by to help as needed.)

8. Call home office - so thatthey can assist as needed incoordinating overall decisions,supply additional experiencedmanpower, equipment, pressreleases, and other companyfunctions. This will then bereported to higher companyofficials and the insurancecompany.

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G. Try to evaluate the cause of theaccident:

1. Possible Causes

a.. Ruptured hose.

b . Ruptured vessel such astank truck, process vesselor line, leak in largestorage tank.

£. A bad or blown pump seal.

<L Pipeline rupture.

2. Course of Action

a_. Wait for NH3 to vaporizeand dissipate.

JD. Consider the use of waterto dilute the NH3 if thespill is not large in sur-face area. Water cancause a much larger vaporcloud. Do not spray waterto dissipate a large sur-face area pool of ammonia.

H. Contact necessary officials:

1. State Regulatory Agency

2. EPA

3. Corps of Engineers

4. OSHA

5. Insurance Claims Office.

These agencies to be notified assoon as possible after emergencyis under control.

II. ORGANIZATION FOR HANDLING EMERGENCIES

In-house planning, local authorityeducation, and surrounding neighborcommunication is a must for the suc-cessful handling of an emergencysituation.

The Owner, terminal manager, or safetydepartment representative should thor-oughly train the sheriff's department,state highway department, civil defense,and surrounding fire departments onthe characteristics of ammonia in a

spill or uncontrolled state. Emphasisshould be made on "always knowing thewind direction." The respective depart-ments or agencies should periodicallybe given plant or terminal tours tofamiliarize themselves with the equip-ment layout.

It is important that a designated per-son be the Emergency Plan Administra-tor. A second person should be equallytrained and prepared in case of absenceof the primary person designated.

Each terminal neighbor should be per-sonally visited by the Emergency PlanAdministrator and his assistant. Theyshould present an instruction sheetfitted in plastic laminate. It shouldbe prepared in simple language andlarge print. The instructions shouldadvise the neighbor of the properthings to do in the advent of an emer-gency at the respective terminal. Itis also suggested that an inexpensiveammonia gas mask such as the 3M ModelNo. 8727 be left for each member ofthe family, plus three additionalunits. Special emphasis should bemade for the neighbors not to panicin an emergency situation.

A check list should be prepared toassist the Administrator and act as areminder not to overlook any importantfunction. The list should be simplywritten and include the telephone num-ber of all assisting authorities. Itshould also include the neighbors cate-gorized in quadrants to speed up crucialnotification based on wind direction.The back side of the check list shouldhave a map of the terminal area thatshows the highways and neighbors, alongwith pertinent data. The check listshould be fabricated with plastic lam-inate and placed in all company vehiclesas well as in other pertinent locations.Also, all terminal vehicles should beequipped with a gas mask, wet suit,goggles, and gloves.

When an emergency arises, the EmergencyPlan Administrator should be notifiedimmediately. The Administrator mustquickly evaluate the situation and thenrefer to emergency check list. The fol-lowing is a suggested sequence:

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A. The operating and maintenance per-sonnel should be dispatched to con-tain or stop the uncontrolled leakin a safe and professional manner.

B. Neighbors in the quadrant affectedby the wind direction should benotified.

C. The state highway patrol departmentshould be advised of potentialhighway danger and request specialhelp on these highways.

D. The sheriff's department shouldbe notified of the emergency andrequest assistance in the public'sinterest.

E. The surrounding fire departmentsshould be called, the number ofwhich should depend on the sever-ity of the spill.

A prepared plan for traffic controlusing volunteer workers until thehighway patrol arrives should beset up at terminals that are inhigh-traffie areas.

In the event of a larger spill,other surrounding industry assis-tance may be helpful. They possiblycould provide additional equipment,manpower, and receive recoveredproduct.

It should be noted that most termi-nals employ only two and at themost three persons per location.This makes the manpower situationweak in the event of an emergency.

The spill nature may be such thatthe local terminal office and tele-phone may not be available. Plansshould be made to use any one ofthe neighbors' telephones or pro-vide an alternate communication sys-tem. Communications can be handledvia telephone, two-way radio, CB ra-dio, public address system, or mes-senger, however the situation lendsitself.

III. HAZARDS AND THEIR CONTROL

A. Physiological Effects of Gaseousand Liquid Ammonia

Since ammonia has a penetrating,

intensely pungent, suffocatingodor and is strongly irritating,there is little likelihood thatone will remain dangerously longin an atmosphere seriously con-taminated with ammonia if one isconscious and able to escape. How-ever, serious injury may result ifescape from the gas is impossible,or if one is subjected to the ac-tion of liquid ammonia (anhydrous).Ammonia exerts mainly a local cor-rosive action and is rarely absorb-ed into the blood stream.

Its greatest danger arises from thefact that it is frequently used incombination with other chemicals asa familiar part of a process and is,therefore, not considered seriouslyas a hazardous agent. That ammoniamay cause severe injury if it isemployed improperly should be evi-dent from the information given inthe sections which follow.

1. Gaseous Ammonia

Ammonia gas in concentrationsof 0.6 to 1 percent by volumeis lethal within a few minutes.Irritation of the eyes, respi-ratory tract, and throat re-sults from concentrations aslow as 0.05 to 0.1 percent; aconcentration of 0.2 percentproduces convulsive coughingand may be fatal after a shortexposure, i.e. less than halfan hour. The maximum concen-tration tolerated by the skinfor more than a few secondsis 2.0 percent, i.e. whensuitable respiratory protec-tion is worn.

The following signs and symp-toms result from exposure togaseous ammonia: Burning ofthe eyes, conjunctivitis, skinirritation; swelling of theeyelids and lips; dry, redmouth and tongue; burning ofthe throat; coughing, and inmore sever causes of exposure,difficult breathing (due, inpart, to a reflex laryngealspasm); tenacious, blood-stained sputum; signs andsymptoms of pulmonary conges-

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tion (pulmonary edema); andultimate death from suffoca-tion (asphyxia), due primarilyto the congestion of all tis-sues of the respirator tract.Inadequately treated casesof severe exposure who havedeveloped pulmonary edema mayoccasionally contract a sec-ondary broncho-pneumonia whichmay be fatal.

2. Liquid Ammonia

Anhydrous liquid ammonia pro-duces severe burns on contact,due not only to its causticaction, but also the freezingeffect produced by the rapidevaporation of liquid ammonia.Also, if the liquid is care-lessly handled so that gaseousammonia is released, all ofthe effects of the gas, aspreviously described, mayresult.

B. Fire and Explosive Hazards

Ammonia is capable of forming flam-mable and explosive mixtures withair within certain limits (16 to25 percent by volume). Such con-centrations are seldom encounteredin practical handling and, accord-ingly, the relative fire and explo-sion hazards are small.

Lighting fixtures and electricalequipment should be vapor-proof.If portable electric lights arenecessary, they should be vapor-proof, grounded, and consist of asingle piece of waterproof cable.They should be plugged in at alocation free from ammonia gas.

Tanks, lines, and equipment shouldbe purged or washed free of ammoniabefore welding by any means. Blankoff lines, do not depend on shutoffvalves.

The presence of oil or a mixtureof ammonia with other combustiblematerials will increase the firehazard. The explosive range ofammonia is broadened by:

1. Admixture of oxygen replacingair.

2. Temperature and pressurehigher than atmospheric.

Ammonia forms violently explo-sive compounds with metallicHg. For this reason, Hgshould not be used as a manom-eter liquid or in pressuregauges on ammonia equipment.Ammonia reacts readily withchlorine and when chlorineis in excess, the violentlyexplosive compound NCI3 isformed.

Extinguishers: Ammonia is solublein water. Hose streams are compar-atively effective in removing thegas from the atmosphere.

C. Personal Protective Equipment

1. General

No personal protective equip-ment is an adequate substitutefor safe working conditionsand carefulness on the partof individual employees. Fur-ther, if personal protectiveequipment is to be used effec-tively, each worker must befully informed with respectto its proper employment andtrained in its use.

2. Respiratory Equipment

All respiratory equipment mustbe approved by the UnitedStates Bureau of Mines for theuse to which it is to be putand must be used in strictcompliance with the instruc-tions issued by the Manufac-turer.

Suitable respiratory protec-tion is needed if even smallconcentrations of ammonia areto be encountered. For con-centrations of ammonia gas notexceeding 3 percent and forrelatively brief exposure pe-riods, an industrial gas maskwith full-face mask and greencanister, approved by the

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United States Bureau of Minesmay be used, provided alsothat there is no atmosphericoxygen deficiency and thatadequate skin and mucous mem-brane protection have beenprovided. Such respiratorsshould be readily availableat all points where suchlimited exposures may occur.They are not suitable foremergency use, since in emer-gency the actual ammonia con-centration is unknown.

Where the gas concentrationexceeds 3 percent or is un-known, as in most emergencysituations, or when exposureis prolonged, supplied airrespiratory equipment ofappropriate design with full-face masks, together with pro-tective clothing as indicated,must be used by all personsentering the contaminatedarea. This is true also foroxygen-deficient atmospheressuch as those which existfrequently in storage tanks,tank cars, pits, and sewershandling ammoniacal waste.

Such supplied-air respiratoryequipment consists of approvedtypes of:

ja. Hose masks with or with-out air pump, as may berequired to maintain anadequate air supply (hoseinlet must be in a vapor-free atmosphere).

JD. Air line masks with com-pressed air supply, equip-ped with a suitable filterand a proper reducingvalve or other design de-signed to effect deliveryof air to the face pieceunder optimum pressure.

NOTE: Hose or air line masksare suitable for use onlywhere conditions will permitsafe escape in case of fail-ure of the air supply.

£. Self-contained breathingapparatus with proper re-ducing valve and filter,containing an adequatesupply of stored oxygenor air (such equipmentallows greater mobilitybut usually requires moretraining for its properemployment).

Inspections: Gas masks andother respirator protectiveequipment must be inspectedat regular intervals andshould be cleaned and ser-viced after each use. Itis particularly importantthat canisters and oxygencylinders be replaced beforethey become exhausted.

3. Rescue Harness

A safety belt and life lineshould be used in every casewhere the wearer of respira-tory equipment enters a con-fined, irrespirable atmosphere.A man should be stationed out-side the contaminated area toact in case of an emergency;this attendant should also beprovided with adequate protec-tive equipment in case it be-comes necessary for him toenter the contaminated area.

4. Eye, Skin, and Mucuous Mem-brane Protection

The following protective equip-ment should be used as requir-ed for protection of the eyes,skin, and mucous membranes:

a_. Cotton shirt, trousers,and underwear (cotton re-sists alkalies better thandoes wool).

Jj. Rubber boots, gloves,apron, and coat (rubberis more resistant toalkali than is leather).

c_. Rubber or felt hat withbroad brim.

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d.. Safety goggles of anapproved type.

For optimum protection, thecollar should be kept button-ed, gove gauntlets should betucked inside of sleeves, andtrouser legs should be leftoutside of boots.

In areas of high ammonia con-centration, ammonia may con-dense on any body area subjectto perspiration, even thoughappropriate protective cloth-ing is worn. The severe dis-comfort caused by such con-densation may be minimized orprevented by the applicationof protective oil to such bodyareas in addition to the wear-ing of protective clothing.

CAUTION: Protective creamsalone do not afford adequateprotection.

D. Prevention of Injuries and theControl of Hazards

1. Ventilation

It is of primary importancethat adequate ventilation beprovided and maintained tokeep the concentration ofammonia gas below 100 ppm byvolume in air. Higher concen-trations are dangerous forthe unprotected worker (seefollowing table).

Although special ventilatingsystems will not be foundnecessary in most processes,rooms into which ammoniamight escape should haveventilating ducts leading tothe outside so that escapinggas will not contaminate ad-joining areas or bar theescape of persons who maybe working in them.

2. Periodic Inspections

There should be regular,stringent inspection of allequipment and procedures em-ployed in processes in which

ammonia is manufactured, used,or transported to check theservice ability of equipmentand safety devices and toevaluate potential hazards.

3. Physical Examination ofEmployees

Although most employees maybe assigned with impunity toprocesses in which ammonia isused, it is recommended thatthose with chronic lung dis-ease, e.g. tuberculosis, bron-chitis, asthma, pollinosis,be excluded from such work.Individuals who are known tobe unusually sensitive to am-monia should also be assignedwork in which exposure toammonia in any form is notpossible. Special periodicphysical examinations arenecessary.

GaseousConcentration

(ppm)

25

100

400

1,720

5,000 to 10,000

Effects onUnprotected WorkersExposure Period

Least detectable odorPermissible for 8-hourworking exposureNo adverse effects foraverage, unprotectedworkerCauses irritation ofthroatCauses irritation of eyesOrdinarily no seriousresults following infre-quent short exposures(less than 1 hour)Causes convulsive coughingNo exposure permissible(may be fatal after shortexposures - less than 1/2hour)Causes respiratory spasm,strangulation, asphyxiaNo exposure permissible(rapidly fatal)

4. Conduct in an Emergency

When trapped in an atmosphereof ammonia and while seekingan escape to fresh air, re-frain from breathing for aslong a time as possible.

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Should it become necessaryto breathe before respiratoryequipment can be secured andadjusted, take only short,shallow breaths.

IV- FIRST AID AND MEDICAL TREATMENT FORAMMONIA

A- General Principles

Speed in removing ammonia from con-tact with the patient and in movingthe patient to an uncontaminatedatmosphere is of primary importance.In all cases of severe injury, calla physician at once, giving him acomplete, accurate account of theaccident. Until the physicianarrives and after having accom-plished as thorough removal of theammonia as possible, keep the pa-tient comfortably warm quiet. Takesuch specific actions as may beindicated.

B. Specific Actions

1. Inhalation

A worker who has been overcomeby gaseous ammonia must becarried at once into an uncon-taminated atmosphere and effec-tive artificial respirationinitiated immediately ifbreathing has ceased. A phy-sician should be called atonce. In order to preventthe development of severelung congestion (pulmonaryedema), 100-percent oxygenshould be administered assoon as possible after asevere exposure. Oxygen ad-ministration is most effectivewhen expiration is made againsta positive pressure of 6 cm(about 2-3/8 inch) of water.They may be accomplishedreadily by use of a rubbertube connected to the outletvalve of a snugly fittingface mask and inserted to adepth of not more than 6 cmbelow the surface of waterin a suitable container. Thepressure resisting exhalationshould be adjusted to the pa-tient's tolerance by varying

the depth of the end of thetube below the water's surface.Oxygen inhalation must be con-tinued as long as necessary tomaintain the normal color ofthe skin and mucous membranes.In cases of severe exposure,the patient should breathe100-percent oxygen under posi-tive exhalation pressure forone-hal f hour periods everyhour for at least three hours.If there are no signs of lungcongestion at the end of thisperiod, breathing is easy, andthe color good, oxygen inhala-tion may be discontinued.Throughout this time, thepatient should be kept com-fortably warm, but not hot.

Stimulants will rarely benecessary where adequate oxy-génation is maintained. Anysuch drugs or shock treatmentshould be given only by theattending physician. Neverattempt to give anything bymouth to an unconsciouspatient.

2. Contact with Skin and MucousMembranes

All contaminated clothingshould be removed at once.The affected areas should bewashed thoroughly with largequantities of cool water.

Under no condition shouldsalves or ointments be appliedto skin or mucous membraneburns during the 24-hour peri-od following the injury. Dur-ing this time, the burnsshould be covered with dress-ings, kept wet continuouslywith a mild oxidizing reducingsolution, such as a saturatedsolution of sodium thiosulfate.The patient should be kept com-fortably warm. For persistentcases of skin irritation orfor serious burns of the skinor mucous membranes, a physi-cian should be consultedimmediately.

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3. Contact with Eyes

Call a physician at once.Immediately begin irrigationof the eyes with copious quan-tities of clean water. Thismay be accomplished by use ofa bubbler drinking fountain,a water hose, or by plungingthe head into any convenientcontainer of water and repeat-edly opening and closing theeyes. Irrigate continuouslyfor 15 minutes; repeat thisprocedure every 10 minutesfor an hour, each time irri-gating for a period of 5minutes.

If readily available, a 5-percent boric acid solutionmay be used instead of water,but irrigation must not bedelayed while such a solutionis sought. Prompt and thoroughirrigation is of primary impor-tance. Continuous cold boricacid compresses should be usedfor cases of severe injury, inaddition to irrigation. Afterthe first 15-minute period ofirrigation is completed, itis permissible as a first aidmeasure to instill two orthree drops of an 0.5-percentpontocaine solution or anequally effective aqueoustopical anesthetic. No oilsor oily ointments should beinstilled unless ordered bythe physician. Ulcers of thecornea should be treated byan ophthalmologist.

WARNING: Signs and symptoms of shock,such as pallor, coldness of the extrem-ities, weak, rapid, or irregular pulse,or stupor, as well as changes in therate and depth of respiration shouldbe reported immediately to the attend-ing physician and treated only asdirected by him.

NEVER ATTEMPT TO GIVE ANYTHING BYMOUTH TO AN UNCONSCIOUS PERSON.

Because ammonia is one of the mostwater soluble of all gases, an abundantsupply of water is the best means ofproviding immediate first-aid treatmentfor exposure to ammonia. Always washcontaminated areas of the body, espe-cially the eyes, thoroughly with waterfor 15 minutes or more. Remove con-taminated clothing immediately underrunning water. In the case of highconcentration of ammonia vapor, alwaysleave the area as quickly as possibleand get upwind from the vapor. Ifsomeone is unconscious, move him intothe fresh air quickly and immediatelystart artificial respiration. Follow-ing first-aid treatment, call a doctorimmediately.

Safety equipment is not an adequatesubstitute for safe working conditionsand carefulness on the part of indi-vidual employees. But if needed,safety equipment should be used effec-tively. To ensure this, each workershould be fully aware of its location,use, and limitations. He should bethoroughly trained not only in theproper operation of the equipment, butalso in his individual responsibilityin case of an emergency. In any injuryresulting from contact with liquidammonia to the eyes or skin, immediateflushing with large quantities of cleanwater is imperative. Placing the in-jured person into a container of cleanwater or under an emergency shower maybe the most practical way of accomp-lishing this. In case of severeinjury, call a physician at once andgive him a complete account of theaccident, after following first-aidtreatment.

Exposed persons should be removed atonce to an uncontaminated area. Ifthe exposure has been to minor concen-trations for only a limited time,usually no treatment will be required.

When there is severe exposure to higherconcentrations and if oxygen apparatusis available, oxygen can be administer-ed but only with a person authorizedfor such duty by a physician. If thepatient is not breathing, an effective

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means of artifical respiration shouldbe initiated immediately. Call aphysician.

The patient should be kept comfortablywarm but not too hot and should be keptquiet.

If liquid anhydrous ammonia has beenswallowed, call a physician immediately.If the patient is conscious and able,he should drink large amounts of waterto dilute the chemical. Do not inducevomiting if the patient is in shock,extreme pain, or is unconscious. Ifvomiting begins, place the patient'sface down with head lower than hips.This prevents vomi tus from enteringthe lungs and causing further injury.

Speed in removing ammonia from contactwith the patient and in moving the pa-tient to an uncontaminated atmosphereis of primary importance. If skin con-tact is extensive and emergency showersavailable, the person should get underthe shower immediately. Contaminatedclothing and shoes should be removedunder the shower. In other instances,flushing with large amounts of runningwater should be continued for at least15 minutes.

Under no condition should salves orointments be applied to the skin ormucous membrane burns during the 24-hour period following the injury unlessprescribed by a physician. Subsequentmedical treatment is otherwise the sameas for thermal burns.

If even small quantities of ammoniaenter the eyes, they should be irri-gated immediately and copiously withwater for a minimum of 15 minutes. Theeyelids should be held apart during theirrigation to ensure the contact ofwater with all the tissues of the eyesurfaces and lids. A physician shouldbe called at the earliest possible mo-ment. After the first 15-minute periodof irrigation, if a physician is notavailable, the irrigation should con-tinue for a second period of 15 minutes.It is then permissible as a first-aidmeasure to instill 2 of 3 drops of 0.5-percent pontocaine solution or anequally effective aqueous topical anes-thetic. No oils or oil ointment should

be instilled unless ordered by a phy-sician. The employee should be sentto a physician, preferably an eyespecialist, as soon as possible.

Physicians treating for exposure toammonia should be aware that there isno specific treatment for overexposureto anhydrous ammonia vapors or directlocal contact.

C. Oxygen Administration

Oxygen has been found useful inthe treatment of inhalation expo-sures of many chemicals, especiallythose capable of causing eitherimmediate or delayed harmfuleffects in the lungs.

In most exposures, administrationof 100-percent oxygen at atmo-spheric pressures has been foundto be adequate. This is bestaccomplished by use of a face maskwith a reservoir bag of the non-rebreathing type. Inhalation of100-percent oxygen should not ex-ceed one hour of continuous treat-ment. After each hour, therapymay be interrupted. It may bereinstituted as the clinical con-dition indicates.

It is believed that superior re-sults are obtained when exposuresto lung irritants are treated withoxygen under an exhalation pressurenot exceeding 4 cm water. Masksproviding for such exhalation pres-sures are obtainable. A singletreatment may suffice for minorexposures to irritants. Someobservers feel that oxygen underpressure is useful as an aid inthe prevention of pulmonary edemaafter breathing irritants.

In the event of an exposure caus-ing symptoms or in the case of ahistory of severe exposure, thepatient may be treated with oxygenunder 4 cm exhalation pressure fora one-half hour period every hour.Treatment may be continued untilsymptoms subside.

CAUTION: It may not be advisableto administer oxygen under positive

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pressure In the presence of Impend-ing or existing cardiovascularfailure.

1. The patient should be keptcomfortable and warm, but nothot.

2. Stimulants will rarely benecessary where adequateoxygénation is maintained.

Any such drugs for shock treatmentshould be given only by the attend-ing physician. Never attempt togive anything by mouth to an uncon-scious patient.

V. SAFETY TRAINING

The formal safety program consists ofregular meetings of all personnel in-volved with the operation and mainten-ance of the terminal. These meetingswill be held on a monthly basis toinclude the following subjects:

A. Accident Prevention

1. Review of accidents since lastmeeting - emphasizing thecause and how the accidentcould be prevented.

2. Review of monthly terminalinspection and test programswith respect to possible needfor repairs or changes inoperating practice.

3. Review of accident reportsfrom other terminals or pub-lished safety reviews.

B. Safety Equipment - Protective

1. Safety goggles

2. Gloves - chemical

3. Respirators

4. Safety shoes

5. Hard hat.

C. Plant Emergency Equipment

1. Safety showers

2. Eyewash fountains

3. Tubs.

D. First-Aid Equipment and Procedures

1. For cuts

2. For fire burns

3. For ammonia exposure:

a_. Eye

b. Respiratory

c_. Skin.

VI. ACCIDENT PREVENTION

A. Daily Terminal Inspection

On his periodic inspection toursof the plant, the operator shouldbe alert to the following:

1. Leaks are first of all a po-tential safety hazard andtheir source and potentialseverity must be traced.Additionaly, product may belost and surrounding areasand equipment may sufferdeterioration.

2. Pipe strain affects not onlythe pipe itself but vesselflanges and nozzles andinstrument functioning. De-tection may sometimes be dif-ficult. Foundation settlingor frost heaving give a clueto potential changes in pipestrain.

3. Safety valves must be freelyaccessible and unencumbered.They should'be observed forpossible leakage and testedon a periodic schedule.

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4. Level indicators must be in-spected periodically to makecertain they are giving acorrect reading.

5. Vents and flares must beaccessible with all valvesfreely operable.

6. Electrical grounding connec-tions must be checked by anelectrician or experiencedperson at regular intervals.

7. Emergency shutoff valves mustbe operated periodically.

8. Memorize the location of safe-ty eyewash fountains, safetyshowers, fire extinguishers,fire hose or hose carts, firehydrants, safety ladders andmasks, blankets, and first-aidsupplies. Check their condi-tion and accessibility.

B. General Instructions

Operating personnel should observeall of the following safety prac-tices. These are general in natureand are applicable under all condi-tions.

These instructions have been pre-pared as a guide for those con-cerned with the initial startupand normal operation of thesefacilities.

These instructions, however, do notpreclude any instructions issuedby the Company.

1. Personnel Coverage

Whenever possible, at leasttwo men shall be present ina plant which is operating.Where this is not possible,a system for periodicallychecking on the safety of thesingle man must be initiated.Two men are mandatory whenentering an area where thepossibility of a hazardousatmosphere is great enough towarrant the use of respiratoryprotection.

2. Housekeeping

Good housekeeping goes hand-in-hand with safety. Goodhousekeeping can be maintainedby observing the followingpractices:

a. Keep the work area cleanat all times.

b_. Keep aisles, stairs, andplatforms clear at alltimes.

£. Use proper receptaclesfor disposal of allwaste material.

cL Store tools, equipment,and materials in a neatand orderly way.

£. Prevent or eliminate con-ditions which impair foot-ing, visibility, judgment,protection, or escape.

3. Personnel Protection Equipment

The use of personnel protec-tive equipment is urged undermany circumstances for theprotection of the eyes, hands,and other parts of the body.

a_. Eye Protection

Eye protection shall beon the operator's personat all times while in theoperating area. Propereye protection must beworn when handling acid,caustic, or other danger-ous materials; when work-ing where materials maysplash; when workingaround open lines orbreaking into lines; whenaround grinding, chipping,cutting, drilling, ordusty work; when strikinga hammer to another objectwhich may cause a chip tofly; when sampling linesunder pressure or operat-ing drain and vent valves.

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k- Respiratory Protection andMaintenance of Life-Sustaining Atmosphere

Air masks, dust masks,and gas masks are to beused as conditions dic-tate. Extreme care mustbe used in analyzing eachcase to ensure the adop-tion of measures whichare exactly appropriateto the situation.

£. Protective Clothing

Suitable rubber or plasticcoats, pants, boots, andhoods shall be worn whenworking on lines or equip-ment which contain hazard-ous materials.

Gloves protect your handsfrom cuts, burns, chemicalburns, etc., and shouldtherefore be worn at alltimes while operating.Well fitting clothes shallalways be worn. It isrecommended that safetyshoes be worn at all timesin the plant.

d.- Safety Belts

Safety belts shall be wornwhen working in hazardouslocation such as:

(1) On peak roofs, slop-ing roofs, tanks, orvessels which areslippery and not pro-tected by a railing.

(2) In tanks, tank cars,or closed chambers.

(3) At high elevationswhen full protectionsuch as platforms andrailings is not pro-vided.

ƒ_• Electrical Equipment

(1) Only authorized per-sons shall be allowed

to enter substations,transformer banks,electrical controlrooms, or other areaswhere ignorance maysubstantially in-crease the hazard.

(2) Replacement of fuses,changes in electricalequipment, or wiringmust be made only byelectricians unlessoperator is certainhe knows the propertechnique.

(3) Grounding connectionson electrical equip-ment are there tocarry stray electri-cal changes to groundand prevent shock topersonnel. See thatthey remain connectedand in good condition.

£• Locking-Out Procedure

Locking and tagging ofequipment shall be donewhen conditions requireit.

When working on movingmachinery, the pushbuttonstation and starter shallbe locked out. A dangertag shall also be tied tothe started and pushbuttonstation signed by the oneworking on the equipment.Any valve which, forsafety reasons, shouldnot be operated shallalso be locked and tagged.Tags and locks shall beremoved only by those thatput them in place.

In entering tanks and ves-sels, there are many haz-ards to be watchful of;lack of oxygen, poisonousgases, explosive mixtures,residual, harmful chemi-cals such as caustic, etc.

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The following shall beobserved when enteringa tank or vessel thathas been in service:

(1) The tank shall bewashed and/or purgedwith inert gas andblown with air,depending on theoperating service.

(2) All lines to the tankshall either be brok-en or have blinds in-stalled. Dependenceshall not be placedon the closing ofvalves in lines tothe tanks.

(3) Before entering,assurance of satis-factory atmospheremust be made.

(4) No one shall entera tank unless anattendant stays onthe immediate out-side at all timesto render aid ifnecessary. The out-side attendant mustbe in sight or com-munication with theman inside at alltimes. A safety beltor line shall be usedby all personnelentering a tank when,in the judgment ofthe operating engi-neer on duty, a haz-ard may exist.

(5) Air masks or airpacks should beavailable at alltimes and used when-ever there is anyelement of hazard.

4. Equipment and Materials

The correct use of equipmentand materials may preventmany accidents. Some speci-fic rules and guides aregiven below:

a_. Ladders and Platforms

(1) Before using any lad-der, inspect it fordefects, especiallycracked or brokenrungs or side rails.

(2) Only one man shouldbe on a ladder at atime.

(3) Nothing should becarried in eitherhand when climbingup or down a verticalstationary ladder.No object is to becarried which wouldprevent both handsbeing used to graspthe ladder. Objectsshall not be carriedin pockets whichmight fall on some-one below.

(4) All straight laddersmust be held untiltied securely at thetop.

(5) Always engage snapspreaders on a step-ladder. Never usea step!adder as astraight ladder.

(6) As our plants areusually not enclosed,care must be taken inusing ladders, stairs,and platforms whenthey are wet.

J . Scaffolds

Should the operator beusing scaffolds duringoperations, they shouldbe inspected for con-struction defects in theplanks, etc., beforebeing used.

c_. Hand Tools

Only tools which are ingood shape should be used.Improper and defective

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tools contribute to acci-dents. The following safepractices should beobserved:

(1) Prevent injuries byusing tools in aproper manner.

(2) Be sure of your foot-ing before using anytool.

(3) Do not use tools thathave split handles,mushroom heads, wornjaws, or other defects.

(4) Do not use makeshifttools or impropertools.

(5) When working over-head, make suretools cannot fallon someone below.Tie them to a lineif necessary.

(6) Use spark-proof toolswhere there are ex-plosive vapors orgases.

Hose

(1) Before using a hose,inspect it for de-fects, cuts, looseclamps, improperfittings, etc.

(2) Never use a waterhose as a substitutefor steam or air hose.

(3) Never apply air froman air hose to anypart of the body orclothing.

(4) Use only standardfittings for allhoses.

Machinery and Guards

Safety guards are fur-nished for personnel pro-tection. The following

regulations must befollowed:

(1) Remove guards onlyafter equipment hasbeen shut down,tagged, and lockedout of service.Replace guards assoon as work iscompleted.

(2) When using machinery,make sure guards arein place and opera-tive.

(3) Be thoroughly famil-iar with equipmentbefore you attemptto operate it.

(4) Do not stand on mov-ing equipment whilein operation.

ƒ_. Personnel Conduct

(1) Smoking shall beallowed only in desig-nated areas. Lightersand matches shall notbe carried within anoperating terminalwhere fire is ahazard.

(2) Horseplay and prac-tical jokes arestrictly forbidden.

(3) Intoxicants of anykind shall not becarried into orused in the terminal.Anyone under the in-fluence of intoxi-cants will not beallowed in the ter-minal area.

(4) Walk on sidewalks;if on the road, onthe left, facingtraffic.

(5) Do not walk undercranes, booms, orloads being hoisted.

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(6) Get first aid or med-ical attention asappropriate for allinjuries, contactswith chemicals, etc.

(7) Practice commonsense, hygiene prac-tices, such as wash-ing before eating,drinking only testedwater, changingclothes regularly,avoiding use of gaso-line, kerosene, andsolvent for washinghands, etc.

(8) Do not jump fromplatforms, ladders,etc.

(9) Wrong lifting methodscause unnecessarystrains which some-times result in her-nias. Observe thefollowing practiceswhen lifting objects:

Be sure you have agood footing.Remove greasy sub-stances from yourhands.Never lift whilein an awkward posi-tion.When lifting fromthe floor, keep armsand back straight,bend your knees,and lift with yourleg muscles.Always ask for helpwhen lifting a heavy,bulky, or awkwardload.

Fire

Know location of fire ex-tinguisher, fire hose, andcall boxes. Know how touse extinguishers andwhich ones to use on vari-ous types of fires. Ensurethat proper fire-fightingequipment is on hand andin good condition.

Assure that inflammablematerials or explosivegases are not presentbefore allowing weldingor cutting operations toproceed. Welding and cut-ting will not be permittedin an operating area with-out approval of the opera-tor on duty. This appro-val shall be obtained bythe use of a welding andcutting permit.

VII. PROPERTIES OF ANHYDROUS AMMONIA

A. Description

Colorless gas, extremely pungentodor, liquified by compression,chemical name is ammonia and com-mon name is anhydrous ammonia.

B. Properties

1. Physical and ChemicalProperties

FormulaColorOdorDensity (Ib.per cu. 38.50feet at 60°F)

Boiling pointB. P. freezing

pointExplosive

limits(percent byvolume in air)

Corrosive

Affinity forwaterLight sensitive

NH3ColorlessPungent

-28°F

-107.9°F

To aluminumalloy galva-nized surfacecopper andcopper alloys.

YesNo

Gas

NH3ColorlessPungent

16 to 25

Same asliquid.

YesNo

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2- Vapor Pressure of Ammonia

PressureTemperature, °F

-50-45-40-35-30-25-20-15-10- 50510152025303540455060708090100110120130140

*Inches of mercury below one standard atmo-spheric (29.92 inches).

VIII. REFERENCE

The following list represents publishedinformation which is readily available.All of these items should be reviewedin the safety meetings and be requiredreading for the operators and mainten-ance personnel at the terminal:

A. "OSHA" Occupational Safety andHealth Act of 1970 (or latestissue). Volume 36 - 1910.111covers "Storage and Handling ofAnhydrous Ammonia."

B. ANSI - K61.1 1972 (or latest issue)American National Standard - "Safe-ty Requirements for the Storage andHandling of Anhydrous Ammonia."

psia

7.678.95

10.4112.0513.9015.9818.3020.8823.7426.9230.4034.2738.5143.1448.2153.7859.7466.2673.3280.9698.06

107.3128.8153.0180.6211.9249.0285.4330.3379.1

Psig

*14.3*11.7* 8.7* 5.4* 1.6

1.33.66.29.0

12.215.719.623.828.433.539.045.052.658.666.374.592.6

114.1138.3165.9197.2232.3271.7315.6364.4

C. National Safety Council Data SheetNo. 251 (Revision A) "AnhydrousAmmonia."

D. API-630 Appendix "R", AmericanPetroleum Institute specificationsfor "Low Pressure Storage Tanks forRefri gérated Products."

E. Chemical Safety Data Sheet SD-8,Manufacturing Chemist Association- "Properties and Essential Infor-mation for Safe Handling and Useof Anhydrous Ammonia."

F. Chemical Safety Data Sheet SD-13,Manufacturing Chemist Association- "Properties and Essential Infor-mation for Safe Handling and Useof Aqua Ammonia."

G. "Recommended Practice for UnloadingFlammable Liquids from Tank Car,"Manual Sheet TC-4, ManufacturingChemist Association.

In addition to the above standard pub-lications, the AIChE "Safety in AmmoniaPlants and Related Facilities" has in-cluded many articles on ammonia storagesafety subjects. Several typical arti-cles of general interest in recentyears would be of particular interestto terminal operators.

H. "Precautions for Ammonia StorageTanks" by E. T. Comeau, Farmland,Volume 14 (1971).

I. "Ammonia Plant Safety Manual" byW. L. Ball, Air Products, Volume13 (1970).

J. "A Measure to Reduce Vaporizationof Liquid Ammonia Spilled into theAtmosphere and the Effect of LiquidAmmonia on Moist Ground" by Dr.Klaus Feind, BASF, Germany.

K. "Use of Fire Fighting Foams onAmmonia Spills" by W. D. Clark,ICI, England, Volume 18 (1975).

L. "Inspection of a 12,000-Ton AmmoniaStorage Tank" by J. M. Truscott andJ. G. Livingstone, ICI, England,Volume 20 (1977).

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M. "Frost Heaves and Storage VesselFoundations" by D. M. Morrison andH. T. Marshall, CB&I, Volume 13(1970).

N. "Storage of Liquefied Ammonia inLarge Storage Tanks at AtmosphericPressure by G. 0. Morgan and J. D.Reed, ICI, England, Volume 7(1964).

0. "Flammability Hazards of UrethaneFoam Insulation" by C. V. Hilden-brand, Volume 12 (1969).

NOTE: The year presented is theyear prior to the year published asshown with-the volume number.

HALE, C.C.

I f , ? :I'j

LICHTENBERG, W.H.

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