regulation safe work practice knpc

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KUWAIT NATIONAL PETROLEUM COMPANY

Ref. No.: HSE-TSOH-10-1363 (Rev : 2) Date of Issue: Oct. 2010Title: Safe Work Practice On Entry & Cleaning Of Leaded Fuel Storage Tanks Next revision date: Oct. 2013

Safe Work PracticeOn 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: Cleaning Procedures And Personal Protection Required 11

APPENDIX-B: Typical Site Layout For Tank Cleaning Facility 12

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

13

Printed copy not controlled



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Safe Work PracticeOn Entry & Cleaning Of Leaded Fuel Storage Tanks

1.0 Introduction

Tetraethyl lead and Tetramethyl lead commonly referred to as TEL and TML are thelead alkyl compounds added in very small quantities to motor gasoline to improve theiroctane rating. The highly toxic properties of lead alkyl compounds (in theirconcentrated form used for blending) necessitate strict observance of safetyprocedures during its handling. Since introduction of lead free gasoline in October1998, the use of lead alkyls has been greatly reduced. In future, it is expected to beeliminated totally.

The precautions may vary somewhat with the nature of the work but are based on thesame general principles. The precautions provided in this document are supplementary

to the requirements of the relevant work permits applicable to the job. Detailed workpractices 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 accumulatedover a period of time. Overall toxic hazard of TEL and TML are similar. It can enter thebody by inhalation of vapor, by ingestion of the liquid and absorption of the liquidthrough the skin.

2.1 Threshold Limit Value-Time Weighted Average Concentration

The maximum permissible time weighted average concentration in air over an eighthour workday, known as TLV-TWA, for TEL is 0.1 mg(lead)/m3 ( 0.0075 ppm organiclead 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 0.1mg(lead)/m3 shall be adhered to.

Measurement of concentration of organic lead vapors in air can only be made by usinga lead-in-air analyzer. For details of the procedure, reference should be made to OctelHandbook.

2.2 Potential of Exposure

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




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- Leak or spills

- Handling sludge of leaded gasoline tank

- Maintenance work in leaded gasoline tank

- Transferring of TEL/TML from wagons or drums

3.0 Selection of Personnel

It is essential that personnel employed to work involving lead alkyl compounds arephysically fit, medically examined, knowledgeable about their job, have a high sense ofresponsibility and are reliable.

Operations/ Maintenance TL of the area shall ensure that minimum number ofpersonnel required to accomplish the job shall be engaged and hazardous operationsshould be shared equally among the members of a team to prevent the possibility ofexcessive 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 alkylsare medically supervised to ensure that they are not affected due to any exposure. Allpersonnel associated with TEL/TML jobs shall undergo an initial medical check up andsubsequent check-ups twice yearly (or more frequently if warranted by the level ofexposure). This facility is available at KNPC Clinic and personnel assigned to jobsinvolving 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) toconcerned individuals by the Medical Services Div. to certify that the bearer is medicallyfit to work on equipment, using appropriate PPE, where potential of exposure toTEL/TML exists.

Personnel working on such equipment shall be in possession of a valid medicalauthorization 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 dependon conditions under which it is being used.

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




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4.1 Cartridge Respirator

a. Cartridge respirator provides adequate protection in open areas. These arerecommended for normal operations on blending plants and for work outsidemanholes 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 tankor 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 ofcartridge 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.

4.2 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 confinedspace 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 mm OD and made of Teryleneor Nylon reinforced PVC or wire reinforced PVC.

c. Air to the respirator shall be supplied by a compressor situated outside and upwindof contaminated area through a suitable filter to remove oil, moisture, dust and shallhave CO & CO2 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 ofengines and any other source of noxious gases.

4.3 Self-Contained Breathing Apparatus

Pressure demand type SCBA provides complete mobility to the wearer and isrecommended for emergency use in case of fire or spills. Airline respirator provides thesame degree of protection but is less suitable because of the possibility of hose beingdamaged 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 ahigh degree of safety and comfort, particularly in hot climate.

b. The air-supplied suit shall be fabricated form Neoprene-proofed Terylene cloth andtested to meet the severe conditions encountered during tank cleaning. The air tothe helmet and suit shall be supplied from a compressor via a regulator at an

average flow rate of 10-12 scfm (17-20 m3/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.

c. An emergency supply of bottled air shall be available with the suit for escapepurpose 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 madeof PVC, inner wall of minimum 3.2 mm thickness made of polyurethane and terylenefabric reinforcement between inner and outer walls.

5.0 Protective Clothing

In addition to respiratory protection, protective clothing is also required for all personnelengaged in the handling of lead alkyl compound. The degree of protection required willvary 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 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 ordisconnecting lines or in case of any emergency in open area.

c. Before leaving the area, personnel shall remove gloves, respirator and overallsand shall wash their hands thoroughly with soap and water. Gloves shall be keptclean and dry.

d. If an emergency involving spillage contaminates the clothing, the same shall beburned. The person shall shower himself thoroughly using soap and water beforereporting for medical check up.

e. If any mechanical or design problem results in spillage during unloading, headcovering, rubber boots, PVC suit, PVC gloves, PVC sleeves and canisterrespirator shall be used until the problem is resolved.

5.2 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 andwater. Gloves shall be kept clean and dry.




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

5.3 Maintenance Jobs

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

b. All personnel shall shower thoroughly with soap and water as mentioned earlierbefore leaving the area.

c. After use clothing shall be cleaned and laundered.

6.0 Tank Cleaning

The cleaning of tanks that contain or have contained leaded gasoline is a hazardousoperation due to the presence of flammable and toxic vapors in the tank. The sludgeand scale removed from tank is also hazardous because of presence of toxic leadcompounds. In order to safely carry out the job of tank cleaning and sludge disposal, itis 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 aregiven in Appendix-A for reference.

a. All PPE shall be approved by 3 rd party PPE certifying agencies like INSPEC,SGS orSEI to appropriate international standard.

b. The international standards related to the PPE are given below.

S.No PPE Standards

1 Respiratory Protection NIOSH, AIHA/ANSI Z88 series standards,EN 132,136,137,

EN 14387 latest version2 Safety Boots EN 13832:2006

3 Air supplied suit EN 943-1:latest version

4 Gloves EN 374-latest version

5 Aprons/Coveralls EN 340, 13982,14605 latest versions




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c. Safety boots of natural rubber, Neoprene or PVC having protective toe caps shallbe 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 integralhelmet fed from a compressor through 13 mm bore hose is the most suitableprotective wear for use inside a tank. In hot weather, vortex tube air cooler shallbe used with these suits to provide comfort to the wearer. Air shall be available ata pressure of 100 psig and @ of 15 sm3/hr per person. Normal clothing shall notbe worn under this protective suit and all men shall change their clothing beforecommencement and after finishing the work.

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

g. Personnel working outside the tank shall wear Neoprene/PVC boots, Neoprene-proofed Terylene suit or Neoprene proofed apron or cotton overalls, PVC glovesand cartridge respirators.

6.2 Appointment Of Dresser

a. One man should be appointed as dresser to help men into their protectives and towipe down their suits, gloves and boots by soap solution while they stand in thetray (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 andNeoprene-proofed Terylene Apron/Overall.

6.3 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 ofclean 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 beprovided for cleaning of contaminated clothing. It shall be equipped with drumshaving 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 clothesand 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 otherpurpose.

d. Tray A steel or polythene tray about 4 ft. square and 4" deep, in which men can standon 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 SheetSteel sheets with non slip surface shall be laid on ground at entry/exit manholes toprevent 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 providedwith notices.

6.4 Hoses

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

b. Hose shall be checked daily for physical deterioration and discarded on any visiblesign.

c. Hose due to their immersion in sludge can pick up lead. After every 100 hours ofuse, 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 isdescribed in Octel handbook. If lead content of air is below TLV limit the hoseremains suitable for use, otherwise it shall be discarded.

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




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6.5 Ventilation

Confined space entry procedure shall be followed when preparing a tank for safe entryfor cleaning or inspection.

Sensors used in flammable gas detectors are rapidly poisoned by presence of lead in thegasoline vapors and start giving wrong readings. To ensure accurate detection of leadedflammable vapors, a proper filter designed for lead compounds shall be used on thesampling line.

Ventilation of fixed roof or floating roof tank can be achieved by using an air blower or airextractor. Continuous ventilation shall be maintained throughout the tank cleaningoperation.

7.0 Tank Inspection

After a tank has been cleaned and de-sludged, sufficient organic lead compound is stillpresent on walls and floors of the tank to produce a toxic environment and hencenecessitate use of personnel protective. Personnel entry into the tank for inspections isnormally for short duration and air supplied respirator, cotton overalls and PVC glovesare 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 inthe past shall have the following notice displayed adjacent to all manholes:

THIS TANK HAS CONTAINED LEADED GASOLINE. IT MUST NOT BE ENTEREDWITHOUT COMPLYING WITH THE PRESCRIBED REGULATIONS.

9.0 Disposal Of Leaded Sludge

Sludge of leaded gasoline tank shall be disposed by the method selected and approvedby 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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APPENDIX-A: CLEANING PROCEDURES AND PROTECTION REQUIRED

OPERATION PROTECTION REQUIRED REMARKS

1. Empty gasoline from tank -This stage includesfloating off residualproduct with water

2. Assemble and check allequipment

- -

3. Disconnect and blank offdelivery and suction lines

PVC gloves -

4. Open manholes Air-supplied respirator orcanister respirator, PVCgloves

No respiratory equipmentis required until the joint isbroken

5. Fit ventilation equipment - -

6. Test ventilated tanks withexplosimeter

Air-supplied respirator.Canister respiratorsuitable if the tank is notentered

Continue ventilation at alltimes

7. Fit sludge pump-suction intank at low point

Full protection* -

8. Open clean-outdoors (iffitted)

As 3 above, then air-supplied or canisterrespirator in the laststage

-

9. Hose sludge towards sludgepump suction, but do notenter tank

Air-supplied respirator.Canister respirator maybe used if the doors areon the windward side ofthe tank

Hosing may be omitted,especially where watersupply limited, or disposaldifficult

10. Enter tank if necessary andcontinue cleaning withhoses, shovels, etc.

Full protection*Continue ventilation at alltimes.

11. Inspect Full protection*

Although the tank maylook clean, toxic vapour ispresent for some time

even with good ventilation12. Carry out repairs asnecessary

Full protection clothingContinuous ventilation isnecessary

*"Full protection" means: PVC gloves, rubber or Neoprene or PVC boots and Air-supplied suit and helmet, (with vortex cooler in hot climates) or Neoprene-proofedoveralls, plus air-supplied respirator and head protection.




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APPENDIX-B: TYPICAL SITE LAYOUT FOR TANK CLEANING FACILITY




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APPENDIX-C:




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