NATIONAL THERMAL POWER CORPORATION

OPERATION DIVISION FORMAL DOCUMENTATION SYSTEM

OPERATION GUIDANCE NOTE - OGN/OPS/CHEM/007

Issue No. : 1 Date : March 1994

SAFETY PRECAUTIONS AND OPERATING

PROCEDURES FOR UNLOADING OF
BULK ACID AND CAUSTIC SODA

Approved for
Implementation by ........................................................
Director (Operation)
Date :....................................
Enquiries to : Executive Director, Operation Services

SAFETY PRECAUTIONS AND OPERATING PROCEDURES FOR

UNLOADING OF BULK ACID AND CAUSTIC SODA
CONTENTS
Page Nos.
1.0

Introduction

2.0

Superseded Documents

3.0

Scope

4.0

General procedure and Safety Precautions

for reception and unloading of bulk Hydrochloric
Acid, Sulphuric Acid and Caustic Soda.

4.1

Responsibilities

4.2

Safety

4.3

Reception and Unloading Procedures

5.0

Safety in Handling Chemicals

6.0

Implementation

7.0

Review

8.0

Bibliography

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OGN/OPS/CHEM/007
Issue-1 Mar.-1994

SAFETY PRECAUTIONS AND OPERATING PROCEDURES FOR

UNLOADING OF BULK ANID AND CAUSTIC SODA
1.0

INTRODUCTION
In power stations bulk concentrated hydrochloric acid sulphuricacid and
caustic soda are routinely handled and stored on-site for use during
operation of the water treatment plant and treatment of cooling water.
At most stations the bulk delivery connections for acid and alkali are side
by side with identical flange connectors. It follows therefore that stringent
safety precautions must be taken to eliminate the possibility of putting the
wrong chemical into a tank, because mixing of acid and alkali leads to a
violent and rapid release of heat. Safety precautions are also necessary to
reduce the damage and health risks associated with accidental spillage.
The information contained in this guidance note shall be considered in
conjunction with the NTPC Safety Rules.

2.0

SUPERSEDED DOCUMENTS - Nil

3.0

SCOPE
This document establishes the requirements for the safety and
administrative precautions which need to be taken during receipt and
unloading of bulk supplies of hydrochloric acid, sulphuric acid and caustic
soda at power stations.

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Issue-1 Mar.-1994

4.0

GENERAL PROCEDURES AND SAFETY PRECAUTIONS FOR RECEPTION AND UNLOADING OF BULK HYDROCHLORIC ACID,
SULPHURIC ACID AND CAUSTIC SODA

4.1

Responsibilities

4.1.1

The Incharge (Chemistry )or his nominee will be responsible for ensuring
all administrative, safety and operational procedures are correctly
implemented during receipt and unloading of chemicals.

4.1.2

A competent person nominated in writing by the station Manager will be

responsible for supervising the safe unloading of chemical. This Person
will have sufficient technical knowledge and/or experience to enable him to
carry out work safely and avoid DANGER to himself and avoid creating
DANGER for others.

4.2

Safety

4.2.1

Hydrochloric acid, sulphuric acid and caustic soda are extermely injurious
to skin.

4.2.2

During unloading of the chemincal all pesonnel inside the safety barrier
must wear safety clothing as follows:
i)

A full face shield.

ii)

Acid/caustic resistant overalls.

iii)

Rubber gum boots with overall trousers outside boots.

iv)

Chemical proof gloves with overall cuffs outside gloves.

The tanker driver must wear protective clothing.

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OGN/OPS/CHEM/007
Issue-1 Mar.-1994

4.2.3

The tanker design must be such that the driver or another person can
immediately stop unloading the chemical by a simple operation eg.Closing
the tanker valve or stopping th unloading pump.

4.2.4

Safety barriers must be erected at least 6 m away from the delivery hoses
and connections. These safety barriers must be erected BERORE any
unloading commences and must not be removed until the unloading is
completed.
It should be permanent type of fencing. The platform underneath should be
covered with chemical resistant material with proper draniage provided.

4.2.5

Water douching showers for personnel and water hoses for road washing
must be available near the unloading point and must be clearly coloured
and marked.

4.2.6

Bulk chemicals delivery will be supervised by chemistry staff who will be

responsible for ensuring that the appropriate Station Procedures are
complied with. It is essential that all of these personnel are familiar with
these procedures and their role in the specific activity.

4.2.7

Only one tanker at a time must be unloaded. In the event of a second

tanker arriving on-site whilst the first tanker is unloading, the second tanker
must be parked well clear of the unloading point.
Acid & Alkali unloading systems are function separately. Flanges should be
tagged accordingly to avoid intermixing.

4.2.8

Two sets of keys for padlocks securing the access to area of chemical
storage tanks will be kept. One set by the Incharge (Chemistry) and the
other set by another person nominated by the Station Manager.

4.2.9

A copy of the delivery note from the chemical tanker driver will be used to
identitfy the tanker contents and will also be used as the authority for
unloading the chemical by nominated competent person.
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Issue -1 Mar.-1994

4.3

Reception and Unloading Procedures

4.3.1

There must be safe and unimpeded access adjacent to the unloading

point.

4.3.2

The key will be issued by the Incharge (Chemisstry), or the person in

charge of the other set of keys, to the Nominated competent person after
confirming that the delivery is the correct quality chemical.

4.3.3

The Nominated Competeent Person will read the tanker driver's delivery
note to confirm the nature and quantity of materials to be off-loaded. At the
delivery point he will check that the correct storage tank is selected and
that it has sufficient capacity to received delivery of the quantity to be
discharged.

4.3.4

The Nominated Competent Person will then unlock the padlock to the
chemical storage tank area.

4.3.5

The Nominated Competent Person must wear adequate protective clothing

and confirm that the safety shower function, that the spillage hosing supply
is on, that the appropriate notices and barriers are installed at least 6 m.
from the delivery hoses, and that tanker connections are adequate and
supervise the unloading.

4.3.6

If any leaks are observed during delivery, the transfer must be stopped
immediately, delivery valves shut and the area washed down before
dealing with the leak. The Incharge (Chemistry) must be informed
immediately.

4.3.7

After discharge of the chemical is complete, the Nominated Cometent

Person must close the Filling valve and lock the Padlock on the chemical
storage tank area.

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Issue- 1 Mar.-1994

4.3.8

The Nominated Competent Person must sign the delivery note and retain a
copy with must be immediately passed to the Incharge (Chemistry)

4.3.9

The Incharge (Cheminstry) will record the delivery, and lock away the key.
NO FURTHER KEYS WILL BE ISSUED UNTIL THE KEY IS RETURNED
TO THE INCHARGE (CHEMISTRY), i.e. only one key will be issued at
a time.

4.3.10

In the event of key being lost the incharge (Chemistry) will, with the
agreemeent of the Station Manager, supervise the destruction of the lock
and the fitting of new one.

5.0

SAFETY IN HANDLING CHEMICALS

5.1

Training
Personnel involved in receiving bulk supplies should be trained in the
appropriate Station Procedures. These documents must give details of
hazards precautions, emergency action and first aid requirements.

5.2

Safety Equipment

5.2.1

Sets of safety equipment are to be held at an appropriate number of

positions specified by the Incharge (Chemistry), each set comprising.
a)

Face shields (2 off);

b)

Acid/caustic resistant overalls (2 off);

c)

Acid/caustic soda resistant gloves (2 off);

d)

Rubber gum boots (2 Pairs);

e)

Rope / stands and notices for roping-off area of unloading.

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Issue- 1 Mar.-1994

This equipment is to be checked at the beginning of each shift and any

discrepancies reported immediately to the Shift Chemical Supervisor, who
will be responsible for making good discrepancies as soon as possible.
5.3

First Aid in Case of Contact with Chemicals

5.3.1

Affected Eyes
Immediately irrigate thoroughly with clean water for several minutes (do not
use high pressure water jet).

5.3.2

Skin or Clothing
Immediately drench with water. Remove clothing and wash skin thoroughly.
Wash clothing thoroughly before reuse.

5.3.3

If Swallowed
Immediately wash mouth thoroughly with water. Give plenty of water to
drink followed by:
a)

for Hydrochloric - and Sulphuric Acid - use milk of Magnesia:

b)

for Caustic Soda -use Vinegar, or 1% Acetic Acid.

IN ALL CASES REPORT TO HOSPITAL TO OBTAIN MEDICAL

ATTENTION AT ONCE- reporting the nature of the material.

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Issue - 1 Mar. -1994

5.4

Action in Case of Spillage of Chemicals

5.4.1

Deal with sspillages of chemicals immediately. Remember caustic soda

solutions are greasy and make a floor slippery.

5.4.2

Before dealing with spillage put on face shield, overalls and acid proof
apron, rubber gum boots and chemical proof gloves. Hose down spillage
working from the outside of the spill into the centre. Copious and thorough
flooding is essential. Dilution of concentrated chemicals can cause heating
and spluttering, so great care is necessary.

5.4.3

Ensure unauthorised personnel keep well away from the spillage- ask
Security for assistance in this matter if required.

5.4.4

Inform the Incharge (Chemistry) and Shift Charge Engineer immediately if

there is danger of sizeable quantities of spilt chemicals entering the
Station drains.

5. 4.5

If a large quantity of chemicals enters the Station drainage system, it

should be diluted with large quantities of water in accordance with the
Station Emergency Plan.

5.4.6

Remember acid and alkali in contact with metals can produce a copious
evolution of Hydrogen and produce an explosive hazard.

6.0

IMPLEMENTATON

6.1

Station Managers shall review the adequacy of the Acid and Caustic Soda
handling equipment installed and advise the Director Operations of any
shortcomings.

6.2

Station Manager shall review current Acid and Caustic Soda handling
procedures and, if found necessary in the light of this Guidance Note,
produce and issue new procedures.

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Issue - 1 Mar.- 1994

7.0

REVIEW
The Executive Director, Operation Services, will be responsible for
reviewing the Guidance Note on a 2- yearly basis.

8.0

BIBLIOGRAPHY
1)

NTPC Safety Rues (Electrical and Mechanical) 1988.