Section 1 Chapter XII Safety Aspects & MSDS Printed

Mangalore Refinery and Petrochemicals Ltd, Mangalore Doc No.
DHDT Unit – Phase-3 - Operating Manual F … ….

Section-1-Chapter XII – Safety Aspects & MSDS 20-6-2012
Safety Aspects & MSDS
1. Safety Procedures
1.1 Safety recommendations
1.2 Reaction Protection
1.3 Hazardous and toxic material
2. Plant Safety
2.1 General Remarks
2.2 Potential Hazards
2.3 Toxicity of Gas & Liquids
 Catalytic Dust
 High temperature media
 Explosives and flammable media
2.4 Equipment for protection of personnel
3. Safety Gadgets/provision in the unit

3.1 Fire water system
 Fire Water Main Ring
 Hydrants
 Hose reel
 Fixed water monitor
 Fixed water spray system
3.2 Fire Extinguishers
3.3 Gas detection system
3.4 Plant communication system
 CCTV Details
 Public Addressing System
 Fire call point
 Telephone,
 Walkie talkie
3.5. Emergency Power supply
3.6 Environmental aspects
 Monitoring of pollutants in flue gas
 Liquid Effluent Discharge-CBD
 Flare KOD
 Utility hose stations
3.7 Eye Wash Tower
4. Precautions & Procedures for handling hazards

4.1 Precautions and procedures regarding entry of vessels and tanks.
 Personnel Protection
4.2 Mechanical, Electrical and Plant Operation Hazards
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 Mechanical Hazards, Plant Maintenance

 Electrical Hazards
 Static Electricity
 Atmospheric Electricity
 Electrical Equipment – Plant
 First Aid to Victims of Electric Shock
4.3 Plant Operational – Hazards
 Bypassing of Safety/Critical Systems
 Training
4.4 Fire Hazards
 In case of Fire
 In case of large Fires
4.5 Hazardous Materials/Chemical Handling
 Hydrogen
 Hydrogen Sulphide
 Carbon monoxide
 N2, CO2, Argon
 Hydro treating catalyst
 Carbonyls
 Pyrophoric materials – Iron Sulphide
4.6 MSDS:
 Catalyst-HR 548 specification & properties
 Catalyst-ACT 069 specification & properties
 Inert ceramic ball-1/4” specification & properties
 Inert ceramic ball-3/4” specification & properties
 MSDS for DMDS
 MSDS for MDEA
 MSDS for Sodium Carbonate
 MSDS for Sodium Hydroxide
 MSDS for Ammonia
 MSDS for antifoaming agent (SR 1729)
 MSDS for Lubricity Agent (SR 2036)
 MSDS for corrosion inhibitor (SR 1200)
 MSDS for antifouling agent (SR 1321)

1. Safety Procedures
1.1 Safety recommendations
Plant safety features
General
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Safety is the first consideration for all operations in the plant. Procedures, practices,
and rules have been established as guides to assure a safe working environment.
Safety also plays a major role in the efficient operation of the refinery facilities.
Emergency shut-down
The emergency shutdown is described in section 10.3 of chapter 10. The different
shut-downs are completed by different trips to protect the main equipment and to
prevent any misoperation. Alarms always precede these trips, to allow operators to
take corrective action before the automatic shut-down. For trips and emergency
shut-down refer attachment-1 and attachment-2.
Overpressure protection
Over pressurizing of equipment occurs in many ways. The basic reason for
overpressure is imbalance in heat and material flow in one or more equipment.
Pressure relief valves have been installed after careful evaluation of conceivable
over pressurizing sources.
S. IPF Tag No Service

No No.
LT-333004 A,B,C Detection of high level in FSD (FA-33302)
1 IS-01
UV-33301 Stops feed flow to FA-32302
Detection of High level in Wash Water Drum (FA-
LT-333011A,B,C
33303)
2 IS-09 UV-333007 Stops Boiler Feed Water flow to FA-33303
UV-33308 Stops Process water flow to FA-33303
UV-33309 Allow draining of Process water
Detection of high level in Lean Amine surge drum
LT-333063A,B,C
3 IS-34 (FA-33314)
UV-333032 Stop Lean Amine from B/L
FT-333028A,B,C GA-33302A/B Wash Water pump discharge
4 IS-10 GA-33302A/B Wash Water pump discharge shut off
UV-333006
valve
FT-333082A,B,C GA-33303A/B Lean Amine HP pump discharge
5 IS-13 GA-33303A/B Lean Amine HP pump discharge shut
UV-333031
off valve
 IPF: Instrument Protective Function
High pressure
On high pressure lines, extreme caution must be taken when opening any sample or
bleed valve. Improperly lining up of valves and interconnecting lines may result in
exceeding pressure limits on vessels, exchangers, valves and lines. With improper
operation, the pressure limits on vessels, exchangers, valves, and lines may be
exceeded by thermal expansion of a liquid.
1.2 Reactor Protection

Reactor manufacturer will give the following necessary information for the operation
of the reactor.
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1. A pressure versus temperature diagram indicating where it is possible to

operate the reactor (DC-33301) with:
 Gas containing hydrogen.
 Nitrogen.
2. Rate for pressurizing and depressurizing the reactor (DC-33301). Rate of
temperature increases and decreases accordingly.
3. Maximum allowable difference between the process temperature inside the
reactor and the skin temperature.
4. Location and size of the defects noted on the reactor after fabrication in order
to monitor the changes in these defects over time.
5. Location, size and material of the metallurgical probes to install in the reactor.
The type of tests to perform on these probes will also be indicated.
6. Risk of polythionic acids corrosion.
7. Necessity of degassing the reactor wall.
1.3 Hazardous and toxic materials

The refinery personnel have to be aware of the different materials involved in the
process which are dangerous or toxic. Any chemical used in the plant should have its
toxicity recorded and the first aid labelled.
The following hazardous substances may be present within the plant at various
times:
 Hydrogen (H2)
 Gas oil
 Hydrogen sulphide (H2S)
 Carbon monoxide (CO)
 Carbonyls (Ni(CO)4, CO2 (CO)8,Fe(CO)5, Fe(CO)9, Fe3(CO)12,
Mo(CO)6
 Hydro treating catalysts
 Sulphur dioxide (SO2)
 Iron sulphide (FeS2)
 Nitrogen (N2)
 Ammonia (NH3)
 Sodium hydroxide (NaOH)
 Sulphiding agent (Dimethyl disulfide)
 Anti-fouling agent
 Corrosion inhibitor
 Antifoaming agent
 MDEA
 Soda ash (Na2CO3)
2. Plant safety:
Introduction
This covers hazard & safety guidelines to be followed by all plant personnel during
plant operation. It also covers provisions that have already been incorporated in this
regard. In the following sections, various toxic / hazardous substances have been
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identified and specific instructions have been given for handling of such substances.
Instructions have also been summarized in different sections those need to be
followed in case of release of any of the hazardous / toxic substance to minimize the
adverse affect on the health of the operating personnel.
2.1 General remarks

General rules for the protection of personnel from moving machinery, electricity, and
hot equipment should be observed.
Special hazards pertaining to this plant are the risks of poisoning, fires and
explosions due to the materials handled. Open-air installation of plant reduces the
effects of these risks, and any unnecessary housing of the equipment should be
avoided. Use or storage of combustible materials at the site should be avoided.
In case of unconsciousness, artificial respiration should be applied.
Hand-operated fire extinguishers, fire blankets and emergency showers are placed
according to the requirements. This equipment should be used to fight small fires
and when clothing has caught alight or against burns from chemicals.
In case of fire, it is normal to use water to keep the surroundings cool until the leak
causing the fire can be shut off.
Smoking must be forbidden in all parts of the DHT plant.

1) All sparks should be avoided where combustible gases may be present.
2) Welding should be exercised with regard to the above.
3) The general practices referred to above include:
 Traffic safety
 Fire-fighting
 First aid
 Work permit procedures
 Vessel entry procedures
 Sampling procedures
2.2 Potential hazards

Although essential precautions / steps that need to be taken care of during various
stages of plant operations i.e. start-up, normal operation, shut-down, emergency as
described in relevant chapters, certain potential hazards must be safeguarded all the
time during operation and maintenance of the unit. These hazards are listed below:
 Toxic gases and liquids
 Dust
 High temperature media
 Explosives and flammable media
2.3 Toxicity of gases and liquids
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The refinery personnel have to be aware of the different materials involved in the
process which are dangerous or toxic. Any chemical used in the plant should have its
toxicity recorded and the first aid labelled.
Before handling any chemical / catalyst, it is recommended that operating personnel
should refer to material safety datasheets and catalyst specification provided in this
chapter.
 Catalyst Dust
During operation of the unit, the catalyst is inaccessible and there is thus no hazard
involved.
However, when loading or unloading catalyst, it is most important that the personnel
carrying out the work is dressed in adequate protective clothing, including gloves,
goggles and dust mask or full breathing equipment.
 High temperature media

The DHT process is a high temperature & high pressure process, thus the operating
and maintenance personnel should take reasonable precautions to avoid burning or
scalding.
 Explosives and flammable media

In this category the potentially most dangerous media in the plant are:
- Hydrocarbon vapour
- Hydrogen
The explosive limits and auto-ignition temperatures of flammable media in the plant
are given below
Explosive limit Auto-ignition
temperature
Hydrogen 4.0 -74.2 % vol 560°C
Hydrogen sulphide 4.3 - 45.5 % vol 270°C
Other HCs data are given under fire hazard this chapter itself
The general safety instruction for the plant should contain the necessary prohibitions
against the use of naked flames and instructions about use of spark-free tools, etc.,
during execution of maintenance work in zones where there is a risk of explosive
concentrations of these media.
2.4 Equipment for protection of personnel

For protection of personnel, the following equipment should be available:
1. Safety helmets and shoes, which should be worn by the personnel when
they are in the plant.
2. Goggles for protection against liquids and gases.
3. Gloves for protection against acid and alkaline solutions (rubber) and heat
(ceramic fibre).
4. Respiration masks with filters for dust and poisonous gases.
5. Various clothing as boots, hoods, aprons or full suits for protection against
acid and alkaline solutions, catalyst dust, heat, etc.
6. Ear mufflers or other devices for protection against noise.
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7. SCBA for streams containing H2S sampling.
Hand-operated fire extinguishers, fire carpets and emergency showers should be

placed wherever practical. The extinguishers should be used against small fires, and
the showers should be used when clothing has caught fire. Fire carpets may be used
to extinguish fire in clothing but the victim must be placed under a shower as quickly
as possible - seconds are vital !!!!
3. Safety Gadgets/provision in the unit
3.1 Fire Water System

Following under mentioned areas are covered with fire protection system.
 DHT plant (ISBL & OSBL).
 SS-34
 SRR-37
Fire protection systems considered

Following under mentioned fire protection systems are provided for DHT unit
 Hydrant & monitor system.
 Manual MVW spray system.
 Automatic MVW spray system.
 Water curtain system.
 Fire extinguisher.
System considered and units / area / equipment to be protected

General:
1. Initiation of active fire protection system may be manual / automatic or
a combination of these.
2. Firewater application rates shall be as per TAC / OISD guideline &
NFPA 13 for water curtain application.
System provided:
1. Fire hydrant system extension comprising of ring mains with terminals
as required / applicable, and wet riser to cover technological structures
wherever applicable, hose reel, hydrants accessories and water
monitors.
2. Manually operated MVWS system covering various critical / specified
process equipment handling hydro-carbons.
3. Automatic operated MVWS system for cable caller & compressors
handling hydrocarbon / hydrogen.
4. Automatic operated HVWS systems for transformers TR-34501 & TR-
34502
5. Fire extinguishers.
 Fire Water Main Ring:
Hydrant system
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The hydrant system shall be designed as per TAC for the process unit considering it
to be a ``High Hazard – B” risk and for the sub-station and SSR area as an
``ordinary hazard” risk. The entire system shall also comply with OISD 116
requirements.
The OSBL firewater ring main provided for the entire plant. Firewater shall be drawn
from OSBL firewater ring main, which are pressurized with sufficient water to
ensure an adequate pressure at system flow demand. Ring main shall in general be
laid underground directly buried inside & outside battery limit.
All underground line shall normally be laid 1 meter below ground with pipe suitably
coated & wrapped. All system piping network for inside (ISBL) & outside (OSBL)
shall be under ground, directly buried in loop with isolation valves placed between
every junctions and one isolation valve for every 300 meter of pipe run in such a
way that in case of emergencies / maintenance flow of water can be routed from the
shortest possible route and pipes can be isolated for maintenance purpose. Portion
of the ring mains passing through road crossing shall be provided as per MRPL
specifications.
The ring mains around the process area shall be generally sized to ensure that there
is adequate pressurized water to meet with the single largest fire demand as per
OISD 116 annexure I clause 2.5.
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Fire hydrant system Equipment Details:
 Double headed Hydrants : 23

 Landing valves (FEH) : 17
 Water Monitors (capacity: 2580LPM) : 10
 Long range Remote Operated water/monitor : 6
 Hose Reels : 22
 Hose Box-Yard Hydrants + FEH (13+17) : 30
 Hose Pipes (15M Length/Branch Pipes) : 60/30
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 Hydrants:
Hydrant valve shall be provided throughout the plant to meet the OISD 116
requirement. The same are provided at every 30 meters of perimeter of MRPL-
DHT unit battery limit and for other miscellaneous buildings in high hazard areas at
every 45 meters. Yard hydrants shall be provided at ground level to ensure the
coverage as per TAC.
Each stand post shall be fitted with two single hydrants as a standard throughout the
plant & for future maintenance, a gate valve shall be provided at each stand post
above grade level. Hydrants shall have a minimum pressure of 5.25 kg / cm2 (g).
Restricted orifice plate shall be provided at each hydrant valve inlet to restrict the
pressure to a maximum of 7.0 kg / cm2 (g).
Hydrant valve will cover the area of 30 meters radius horizontally and 15 meters
vertically from its location. Technological structures will be protected with riser as
per TAC clause no 6.3.2. For design pressure, each hydrant shall be considered to
flow water at a flow rate of 36 m3 / hr (600 LPM). Near every alternate hydrant
point a hose box along with accessories (4 x 15 m long hoses, 2 numbers branch
pipe with nozzles) to be placed.
 Hose Reel:
Hose reels shall be considered for location around the building. These shall be
floor / wall mounted type & shall have water connection from hydrant network. Each
hose reel shall have 1” x 40 m long hose. Hose reel in process unit battery limit
shall be provided for quenching of incipient fire.
 Fixed water monitor:

Fixed water monitors are to be placed per OISD requirements where water flow
cannot reach with hydrants. A minimum of two numbers of water monitors have been
envisaged at each such requirement ensuring availability of two streams of flow at a
time, to a column / set of column / technological structure. All monitor shall be
located at a min. 15 meter away from the relevant equipment / structure under
consideration.
For normal monitor & long range monitor, vertical coverage varies with respect to
horizontal distance from equipment to be protected & vertical angle of nozzle of
monitor. It will be ensured that location & elevation of these monitors covers the
height of equipment / columns under protection & operability criteria.
Two nos. of long-range monitors (max. achievable height approx. 60 meter.) are
considered to protect each of the following equipments (total 6 no of long range
monitors)
1. HDS reactor (DC - 33301)
2. Stripper (DA - 33302)
3. Splitter (DA - 33303)
 Fixed water spray system

Following equipments are protected with manual operated, fixed medium velocity
water spray system as per OISD requirement:
1. HDS reactor (DC - 33301)
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2. HP separator (FA - 33304)

3. Cold MP separator (FA - 33309)
4. Splitter reflux drum (FA - 33311)
5. LP HC flare KOD (FA - 33334)
6. HP HC flare KOD (FA - 33340)
7. Feed pumps (GA - 33301 A / B)
8. Stripper reflux pumps (GA - 33304 A / B)
9. Naphtha product pumps (GA - 33305 A / B)
10. Splitter reflux pumps (GA - 33306 A / B)
11. Diesel product pumps (GA - 33308 A / B)
12. Splitter reboiler pumps (GA - 33309 A / B)
13. Kerosene product pumps (GA - 33310 A / B)
14. CBD pump (GA - 33318 A)
15. Reactor effluent air cooler (EC - 33301)
16. Stripper OVHD air cooler (EC - 33303)
17. Diesel product air cooler (EC – 33304)
Automatically operated, fixed medium velocity water spray system considered

for two cable cellar in substation 34 & compressors (GB-33301, GB-33302
A /B).
Nature of design for MVWS / HVWS system:

The design of MVWS shall be generally in accordance with the relevant TAC rules.
System design flow rates and pressure limit range for the nozzle shall be as per
TAC. Velocity in the sub-headers of spray system shall generally not exceed 5
meter / sec.
Water spray nozzles are located in the range of 450 mm to 650 mm from the
external surface of equipments as per TAC Cl. No. 4.6.2.9 of rules of water spray
system. Deflector angle of sprayers will be in line with diameter of vessel to be
protected.
Circumferential spacing of water sprayers for vertical vessel will not exceed 2.5 m
& spraying pattern will overlap with adjoin sprayers pattern. For horizontal vessel
distribution of sprayer in various discharge angles shall be as per TAC Cl. No.
4.5.3.2 of rules of water spray system.
MVWS system for the protection of horizontal vessels is designed to cover the
entire surface of the vessels and appurtenances. Each pump noted above shall be
protected by adequate number of MVW spray nozzles.
Air fin coolers above pipe racks shall be protected by MVWS system which shall be
designed to ensure the minimum flow rate calculated to cover area of each cooler.
Horizontal & vertical arrangement of nozzles will be such as to cover the entire
surface area of vessel. Nozzle of bores less than 6 mm shall not be used.
Maximum run down of 3.5 m is considered for vertical vessel while deciding no. of
rings for water spray system as per TAC Cl. No. 4.6.3.2 of rules of water spray
system. Number of rows required shall be generated by diameter of vessel in
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accordance with the sprayer application chart as per TAC Cl. No. 4.5.2.3 of rules of
water spray system.
Spray systems for different equipment may be grouped according to convenience of

layout and flow limitations. Double feeder system shall be provided to each group of
equipments protected with water spray system in MRPL - DHT plant area. Fire
water take off for water spray system leading to a group of equipments shall be
taken from two independent hydrant headers. Each take off branch for water spray
system shall have dedicated isolation valve followed by strainer as per TAC
practice. The gate valve and strainer for each MVWS system provided at least 15 m
away from the nearest equipment to be sprayed.
Medium velocity spray system provided for cable cellars in substation, SS - 34.
Velocities in the ring mains and sub-ring mains as well as the headers of the MVWS
systems shall not exceed 5 meter / sec.
a. Hydro test pressure:

Hydro test pressure of fire fighting pipe shall be 1.5 times of the system design
pressure.
b. Equipment considered with water curtain system

Water curtain system provided between the Heaters & flow pass control valves to
avoid radiation heat from heaters to flow control valve and other area & also to
dilute vapours due to loss of containment in High pressure section to reach heaters.
Following fired heaters are covered with water curtain system:

1. BA-33301
2. BA-33302
3.2 Fire extinguishers

Fire extinguishers of DCP type of various capacities shall be provided in process
plant area, substation building and in control room as per OISD / TAC requirement
Extinguishers are installed in such a way that person has not to travel distance of
>15meter to reach any Exchanger. 10Kg & 50 Kg Fire extinguishers are installed in
Grade & at all elevated locations, 5kg DCP Extinguishers are provided.
Location of DCP Extinguishers (5 Kg) : 25 No.
1) D-1: DC-33301, 3.7 meter height.

2) D-2: DC-33301, 11.0 meter height.
3) D-3: DC-33301, 18.3 meter height.
4) D-4: DC-33301, 22.3 meter height.
5) D-5: DC-33301, 26.3 meter height.
6) D-6: DC-33301, 30.3 meter height.
7) D-7: DC-33301, 36.8 meter height.
8) D-8: Compressor Shelter, NE corner of GB-33301 (8 meter height).
9) D-9: Compressor Shelter, SW corner of GB-33301 (8 meter height).
10)D-10: TS-1 (6.5 mt), North side of EA-33308.
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11)D-11: TS-1 (6.5 mt), West side of EA-33304.

12)D-12: TS-1 (6.5 mt), Near EA-33311.
13)D-13: TS-2 (6.0 mt), SE corner of FA-33336.
14)D-14: TS-2 (6.0 mt), NW corner of FA-33301.
15)D-15: TS-2 (13.0 mt), NE side of FA-33321.
16)D-16: TS-2 (13.0 mt), SW corner of the platform.
17)D-17: TS-2 (18.5 mt), SE corner of the Platform.
18)D-18: TS-2 (18.5 mt), Near EA-33313/15.
19)D-19: TS-1 (18.0 mt), NE corner of EC-33303.
20)D-20: TS-1 (18.0 mt), East side of EC-33303.
21)D-21: TS-1 (18.0 mt), SE corner of EC-33302.
22)D-22: PR-03 (18.0 mt), NE corner of EC-33301.
23)D-23: PR-03 (18.0 mt), East side of EC-33301.
24)D-24: PR-03 (18.0 mt), SE corner of EC-33301.
25)D-25: PR-02 (18.0 mt), East side of EC-33304
1) D-1: NW corner of GB-33303B
2) D-2: SW corner of BA-33302
3) D-3: South side of DC-33301
5) D-5: North side of EA-33302A/B
6) D-6: East side of EA-33303, near road.
7) D-7: West side of EA-33303/01
9) D-9: East side of GA-33301B
10)D-10: SE corner of GA-33301A
11)D-11: SW corner of FA-33309
12)D-12: East side of GA-33352A/B
13)D-13: East side of GB-33302A
14)D-14: SE corner of GB-33302B
15)D-15: NW corner of GB-33301
16) D-16: SW corner of GB-33302A
17)D-17: East side of GA-33307A/B
18)D-18: SE corner of GA-33312B
19)D-19: NW corner of FA-33306
20)D-20: West side of FA-33308A
21)D-21: SW corner of FA-33307
22)D-22: East side of GA-33308B
23)D-23: East side of GA-33309A
26)D-26: NE corner of GA-33307A
27)D-27: Near GA-33306A/B
28)D-28: Near GA-33312B
29)D-29: East side of GA-33303A
30)D-30: NE corner of FD-33301, below pipe rack.
31)D-31: North side of B/L, Below pipe rack
32) D-32: SW corner of GA-33309B
33)D-33: East side of EA-33305
34)D-34: East side of FA-33331/32
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35)D-35: Near GA-33323/GA-33325A

36)D-36: East side of FA-33334
37)D-37: Near GA-33310A/B
38)D-38: NW corner of EA-33307C/D
39)D-39: West side of EA-33314B
40)D-40: SW corner of DA-33305
41)D-41: SW corner of FA-33331/32
42)D-42: West side of GA-33326B
1) D-1: SE corner of GB-33303A

2) D-2: SE corner of BA-33301
3) D-3: SE corner of DC-33301
4) D-4: North side of XA-33304
5) D-5: North side of GB-33301
6) D-6: East side of GB-33302A
7) D-7: West side of GB-33302A
8) D-8: NE corner of DA-33303
9) D-9: Near GA-33305A
10) D-10: NE side of EA-33306A/B
13)D-13: NE corner of FD-33301, below pipe rack.
14)D-14: West side of B/L
3.3 Gas detection system
DHT unit is provided with number of flammable gas detectors (HC detectors). These
detectors give warning of the flammable gases in the air well before they reach
explosive concentrations. In addition to the HC detectors DHT unit is also provided
with hydrogen detectors and H2S detectors as the unit is handling these gases in
significant concentrations at several locations.
Typically following locations shall be provided with HC gas detectors as per OISD.
1. Light hydrocarbon pumps in process unit.

2. Process cooling tower top platform
3. Fuel gas knock out drum
4. Suction side of FD air blowers located where hydrocarbon vapors may be
present
5. Light hydrocarbon pump stations if located below grade level
6. Recycle gas & make-up gas compressor
In line with above guidelines HC detectors are provided for DHT unit.
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List of all gas detectors (HC, Hydrogen and H 2S) along with its location are
mentioned below
S. Tag No. Type Equipment Location

No.
1 AI-333002 HC BA-33301 Reactor heater FG piping manifold
2 AI-333007 HC BA-33302 Splitter Reboiler FG piping manifold
3 AI-333509 HC FA-33306 Recycle Compressor KOD
4 AI-333505 HC GA-33301A Near Pump seal of Feed pump GA-01A
5 AI-333530 HC GA-33301B Near Pump seal of Feed pump GA-01B
6 AI-333506 HC GA-33309A Near pump seal of Splitter Reboiler
pump
7 AI-333528 HC GA-33309B Near pump seal of Splitter Reboiler
pump
8 AI-333507 HC GA-33308A Near pump seal of Diesel product pump
9 AI-333529 HC GA-33308B Near pump seal of Diesel product pump
10 AI-333510 HC FA-33333 Near FG KOD
11 AI-333511 H2S GA-33304A Near pump seal of Stripper Reflux
pump
12 AI-333527 H2S GA-33304B Near pump seal of Stripper Reflux
pump
13 AI-333512 H2S FA-33306 Recycle Compressor KOD
14 AI-333513 H2S GA-3311A/B In between sour water pump
15 AI-333514 H2S DA-33301 HP Amine Absorber bottom flange
16 AI-333515 H2 GB-33302A 1st Stage MUG, GB-02A
17 AI-333517 H2 FA-33307 MUG 1st stage KOD
18 AI-333518 H2 GB-33302A 2nd Stage MUG, GB-02A
19 AI-333519 H2 FA-33308A MUG 2nd stage KOD
20 AI-333520 H2 FA-33308B MUG 2nd stage KOD
21 AI-333521 H2 GB-33302B 1st Stage MUG, GB-02B
22 AI-333522 H2 GB-33302B 2nd Stage MUG, GB-02B
23 AI-333523 HC FA-33331 On top of grade level for CBD/ABD
FA-33332 Common pit
24 AI-333524 H2S FA-33331 On top of grade level for CBD/ABD
FA-33332 Common pit
25 AI-333525 HC GB-33303A Near Suction take-off of FD fan
26 AI-333526 HC GB-33303B Near Suction take-off of FD fan
27 AI-333555 HC HVAC Duct SRR#37 HVAC inlet duct
28 AI-333556 HC HVAC Duct SRR#37 HVAC inlet duct
29 AI-333557 H2S HVAC Duct SRR#37 HVAC inlet duct
30 AI-333558 H2S HVAC Duct SRR#37 HVAC inlet duct
Hooters:
1) XL-333501 - - Near CBD / ABD common pit
2) XL-333502 - - At grid H11 (north side of FA-33315)
3) XL-333503 - - Main pipe rack north side
15
4) XL-333504 - - Near FA-33320 on pipe rack

5) XL-333505 - - On sub pipe rack east side
6) XL-333506 - - In compressor house
3.4 Plant communication system:

 CCTV Details:
The entire MRPL-DHT unit is covered with CCTV camera for the continuous close
monitoring of the critical equipments. Total 5 No of CCTV cameras are provided in
the MRPL-DHT unit. CCTV camera assembly is suitable for hazardous area
classification (zone-1, gas group IIA /IIB, temp class T6). At following location
CCTV cameras are installed:
1. CCTV-01: Near Grid B3, this covers south side of Battery limit area, flare KOD.
2. CCTV-02: South side of TS-1, west side edge at 34 mt. height. This Covers
column (D-33302, Amine system, top of TS-1) area
3. CCTV-03: Top of PR-3, west side of the Reactor at 33 mt. Height. It covers
Reactor, Heater, Stack, PR-3, Feed pump, Surge drum. etc.
4. CCTV-04: Compressor House, West side of GB-33302A. This covers entire
Compressor house
5. CCTV-05: Near GA-33309B SW corner above 3.0mt from the grade. This covers
Splitter Reboiler pump, Diesel product pump & the bottom portion.
 Public Addressing System
Public address (PA) system is provided for the following areas:
1. MRPL - DHT unit (ISBL)
2. SRR - 37
3. SS - 34 substation
Location of equipments of PA system in SRR & SS building:
1) SRR37-PA-801-001 : Instrument rack room (HGU)
2) SRR37-PA-801-002 : Lobby
3) SRR37-PA-801-004 : Instrument rack room (MRPL-DHT)
4) SS34-PA-801-001 : Cable seller
5) SS34-PA-801-002 : Cable seller
6) SS34-PA-801-003 : Switch gear room
Desktop type call station
1) SRR37-PA-801-003 : Console room
2) SS34-PA-801-005 : Operator room (MRPL-DHT)
3) SS34-PA-801-006 : Operator room (HGU)
Location of equipments of PA system in MRPL-DHT plant area:
1) 333-PA-801-001 : Near to GA-33311A

2) 333-PA-801-002 : Near to GA-33301A
3) 333-PA-801-003 : Near to EA-33301C
4) 333-PA-801-004 : At PR.03
5) 333-PA-801-005 : Near to DC-33301
6) 333-PA-801-006 : Near to DC-33301
7) 333-PA-801-007 : Near to BA-33302
16
8) 333-PA-801-008 : Near to BA-33302

9) 333-PA-801-009 : Near to DA-33303
10)333-PA-801-010 : Near to ECM-3330J
11)333-PA-801-011 : Near to EA-33304
12)333-PA-801-012 : Near to EA-33305
13)333-PA-801-013 : Near to EA-33314A
14)333-PA-801-014 : At PR.02
15)333-PA-801-015 : Near FD-33301
16)333-PA-801-016 : Near to FA-33301
17)333-PA-801-017 : Near to FA-33340
18)333-PA-801-018 / 019 : Near to GB-33302B
19)333-PA-801-020 / 021 : Near to EA-33312A
 Fire call point:

For immediate reporting of any fire/emergency occurrence in the refinery
premises, manual Fire calls points (FCP) of Break Glass type have been provided
all over the plant and off-site areas which can be used at any time to alert the
fire control room. When the glass is broken, the signal goes to the computer
panel at Fire Control Room indicating the particular plant layout and the location
of the call point from where the call was generated. The initiation of any FCP
also gets signaled in the main fire alarm panel located in Central Control Room
also.
Total 15 numbers of Flame Proof Fire call Points installed around the HGU plant.
Location:
 333-MCP-01: South side of GA-33301A
 333-MCP-02: North side of GA-33351A/B, near stair case
 333-MCP-03: Near RGC (9.0 Mt.)
 333-MCP-04: South side of GB-33302B
 333-MCP-05: West side of GB-33302B (9.0 Mt.)
 333-MCP-06: West side of GA-33302B.
 333-MCP-07: North West corner of EA-33321
 333-MCP-08: SE corner of DA-33302
 333-MCP-09: SW corner of EA-33314A, near stair case.
 333-MCP-10: In-between EA-06A/B & EA-05 west side.
 333-MCP-11: NE corner of DA-33303
 333-MCP-12: SE corner of Operator Cabin
 333-MCP-13: NW corner of BA-33301
 333-MCP-14: NW corner of DC-33301
 333-MCP-15: South side of EA-33301C
 Telephone:
Several Flame proof Telephones are installed in and around the plant for
proper communication.
Location details are as follows:
 333-T-01: Near AS-33302 NW corner
 333-T-02: Near PR-02 (East side of EA-33312A/B)
 333-T-03: Near GA-33304A/B, PR-03
 333-T-04: SW corner of BA-33302
 333-T-05: Operator Cabin
17
 333-T-06: In-between EA-33310 & EA-33314B
 Walkie-Talkie:
For effective communication intrinsically safe multiple channels operated Walkie-
talkies provided to the operating staff. Operating staff must tune the right channel
for communication. Separate channels are provided to other units/Departments to
avoid the interference
3.5. Emergency Power supply
Emergency power supply provided to some of the drives to safe guard the Unit &
Catalyst during total power failure. The following equipments are connected with
Emergency power supply.
EC-33302A-P Reactor Effluent Air Cooler : 16X30 KW
GA-33326A/B HP Hydrocarbon Flare KOD Pump : 28.12 KW
GB-33301: GA-51B; RGC, ALOP : 4.68 KW
MOV-333501 Emergency Flare Line : 2.96 KW
GB-33302A-GA-63; GB-33303A ALOP : 15KW
GB-33302B-GA-63; GB-33303B ALOP : 15KW
GB-33301-GAT-52, ALOP: Surface Condensate Pump ALOP
GB-33318, CBD pump
3.6 Environmental aspects

MRPL have considered all basic aspects for environmental protection as per
applicable statutory / legal requirements during the conceptualization, evaluation and
execution of this project & will be continued for the safe Operation. For example,
provision of flare KOD, CBD / ABD system, fired heater stack, flue gas monitoring,
etc., reflect some of these essential ingredients. In addition to above, some of the
specific systems that have been provided to take care of environmental protection
are described below.
 Monitoring of pollutants in flue gas

Flue gas from fired heaters (BA-33301 and BA-33302) may contain NOx, SOx, SPM,
and unburnt HC which are air pollutants. Fired heater burners are designed for low
NOx type of burners that minimizes emission of these pollutants. Following on-line
analyzers are provided at the common Stack (CA-33301) of both fired heaters.
 NOx analyzer, AI-333508A
 SOx analyzer, AI-333508B
 SPM analyzer, AI-333503
In addition to these, sample connections are provided for pollution monitoring.
Following on-line analyzers are also provided at the radiant arch section of each
Heater to detect of an incomplete burning operation:
 CO analyzer, AI-333502 (BA-33301), AI-333504 (BA-33302)
 O2 analyzer, AI-333004 (BA-33301), AI-333009 (BA-33302)
For discharging flue gas into atmosphere, fired heater common stack, CA-33301 has
been provided. The height of stack is determined so as to discharge pollutants at a
safe location into the atmosphere.
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 Liquid Effluent Discharge

 CBD:
In order to protect operating personnel from any hazard due to flashing of lighter
components into atmosphere, all liquid HC drains have been routed to a closed
system called closed blow down (CBD) system & all amine (lean & rich) line drains
have been routed to closed amine blow down system (ABD).
CBD system includes CBD drum, FA-33331 and underground pipes for routing of HC
drains to CBD drum (FA-33331) from various sources. CBD drum is floating with
flare header and is at atmospheric condition (normally). Hence lighter components
that may get generated due to flashing in the CBD drum (FA-33331) can be directly
routed to flare system (closed system) thereby exposure of operating personnel to
such lighter components can be totally eliminated. Liquid HC as collected in CBD
drum (FA-33331) is pumped outside the plant battery limit for further treatment.
1” Utility connection & 1” Flushing oil connections (10 numbers) are provided in
CBD network (close to the beginning of main header & sub header) to remove/flush
the heavy HC from CBD drum (FA-33331) during shut down prior to opening of this
drum. Also CBD drum (FA-33331) is provided with steam coil & necessary LP steam
connection to prevent the congealing of HCs at the bottom of the drum.
Note-1 (HR-200): While carrying out any maintenance activities inside the
CBD valve pits, H 2S concentration should be monitored once in an hour by
using H 2S detectors & ensure that the H 2S level is in acceptable limit.
Note-2 (HR-198): Before draining any Hydrocarbon to CBD, Operator as to

ensure the draining material temperature is below 150°C. If not the material is
to be cooled down to 150°C before draining. Temperature of the draining
material to be monitored by Local temperature gauge TI-333653.
 ABD
ABD system includes ABD drum, FA-33332 and pipes for routing of amine drains to
ABD drum (FA-33332) from various source. ABD drum (FA-33332) is floating with
flare header and is at atmospheric condition (normally). Hence amine vapours that
may get generated in ABD drum (FA-33332) can be directly routed to flare system
(closed system) thereby exposure of operating personnel can be totally eliminated.
Liquid amines are collected in the ABD drum (FA-33332) is pumped outside the
plant battery limit for further treatment. LP steam connections are provided in all
clean-out pits for ABD headers and sub header for purging.
For routing of non-hazardous liquid drains, OD system and CRWS system have also
been provided. These systems are open to atmosphere. Drains are collected and
routed outside plant battery limit for further treatment/recovery.
Note. (HR-200): While carrying out any maintenance activities inside the ABD
valve pits, H 2S concentration should be monitored once in a hour by using H 2S
detectors & ensure that the H 2Slevel is in acceptable limit.
 Flare KOD
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In case of abnormal situations like fire, system blockage, power failure etc. process
systems /equipments are likely to get pressurized which in turn get blown away
unless measures for timely depressurization are provided.
In order to protect the system / equipment in case of abnormal situations as

explained above, relief valves have been provided at appropriate places for releasing
the contents of a system /equipment to a system, which is at lower pressure thereby
reducing the pressure of the system /equipment under danger.
Discharge of relief valves can be directly routed to atmosphere in case of non-

hazardous substances i.e. water, steam etc. However, HC gases from relief valve
must be routed to a closed system (flare KOD) to protect the operating personnel
from any potential hazard. Following three flare systems are considered for DHT
plant:
1. HP flare system
2. LP flare system
3. Acid flare system
HP Flare System:
HP flare system consists of a HP HC flare KOD (FA-33340) and a main HP flare
header in which individual HP relief valve discharge is being tapped. This header is
connected to HP HC flare KOD (FA-33340) to separate out liquid from HC gases
before sending these gases to the OSBL HP HC flare system. All liquids collected in
the HP HC flare KOD (FA-33340) are discharged to the slop header at OSBL via HP
Flare KOD bottom pump GA-33326A/B.
LP Flare system :
LP flare system consists of a LP HC flare KOD (FA-33334) and a main LP flare
header in which individual LP relief valve discharge is being tapped. This header is
connected to LP HC flare KOD (FA-33334) to separate out liquid from HC gases
before sending these gases to the OSBL. All liquids collected in the LP HC flare KOD
(FA-33334) are first discharged to CBD header through UV-333503 and then further
pumped to slop header from CBD.
Acid gases flare system:

Acid gas flare system consists of a main acid gas flare header in which acid gas
relief from sweet gas KOD (FA-33313) and sour water degassing drum (FA-33315)
are being tapped. This header is routed to OSBL acid gas flare network.
Flare line isolation valve always installed with stem in Horizontal or pointing
downward position to avoid free fall of gate & blockage of Flare system.
 Utility hose stations
Utility hose station contains LP steam connection, plant air connection and service
water connection depending on its location. These hose stations are provided in view
of criticality of the equipments, plant lay out and good engineering practice.
20
Service water connection provided in a hose station is typically useful for washing /
flushing of floors. These connections can be utilized for flushing of equipments also
in case of maintenance. Other application for this connection is hydro testing of
equipments.
LP steam connection provided in a hose station is typically useful for fire fighting of
hot flanges. It can be used for dispersion of HC cloud in case of HC release. Other
application for this connection is flushing / purging of equipments, piping etc.
Plant air connection provided in a hose station is typically useful for purging of
equipments /system. Other application for this connection is to create oxygen rich
environment in enclosed equipments like reactor etc. during maintenance.
3.7 Eye Wash & Safety Shower.

Eye wash & Safety Showers are installed near the chemical preparation/Dosing
system. In case of any chemical flash to the operating staff, he/she as to rush below
the eye wash/safety showers to wash out the contaminants. It serves by spraying
sufficient water to remove the contaminants from Eyes or the body.
Have a regular check at predetermined intervals say once a day to confirm proper
functioning of safety showers and eye washers. Any defects should be made good at
earliest.
Location of the Eye Wash & Safety Showers:
1) EWSS-01: Near Anti foam injection package, XA-33301.
2) EWSS-02: In-between FA-33308A & B.
3) EWSS-03: Near Anti fouling agent dosing system, XA-33302.
4) EWSS-04: South side of Neutralisation pit.
5) EWSS-05: East side of GA-33308A/B.
4. Precautions & Procedures for handling hazards
4.1 Precautions and procedures regarding entry of vessels and tanks.

(In which hazardous materials has been present). Following precautions shall be
taken:
(I) The vessel must have been purged with Nitrogen steamed out, or flushed with
water until all hazardous materials have been removed. The hose used for
flushing must be equipped with a check valve.
(ii) The vessel or tank man ways may be opened only after obtaining a written
permit from the authorised person.
Vessels/tanks containing materials with pyrophoric iron sulphide will reheat
spontaneously, even after being soaked with water releasing obnoxious fumes as
well as flammable materials. Such material with iron sulphide must be removed from
the vessel/tank in a safe manner.
(iii) After purging check with explosive meter and if explosive gas is present the
vessel has to be boxed up and purging has to be continued until it is free of
explosive gas.
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(iv) The vessel has to be totally isolated from connected piping and equipments by
inserting spades/blinds.
After purging and after sufficient air ventilation ensure required oxygen content by
oxygen analyser or detector. The vessel entry permit shall contain all the details,
measures to be taken while a person is in the vessel.
(v) When a person is inside a vessel or tank at least one man (equipped with air
breathing apparatus) shall be outside the vessel, keeping in constant contact and
ready to give assistance.
(vi) Incase of welding, apart from the welding procedures and precautions, the area
has to be free of inflammables, combustibles. The electrical earthing has to be
properly routed. The maintenance work must always be supervised to ensure
safety.
(vii) Electrical equipments in particular should only be opened by electrical
personnel holding valid permits only when properly isolated.
 Personnel Protection
Safety gadgets like hard helmets, suitable gloves, protective clothing, goggles, gas
masks, air/oxygen breathers, safety belts must always be used as applicable when
handling harmful chemicals or entering areas where harmful chemicals can be
released. Adequate douche facilities, eye washes and other first aid equipment
should be located within close proximity to areas where hazardous conditions might
arise accidentally. Where such permanent facilities are not available make shift
alternatives must be provided.
Have a regular check at predetermined intervals say once a day to confirm proper
functioning of safety showers and eye washers. Any defects should be made good at
earliest.
Particulars regarding personnel protective equipments:
 Protective equipment is not a substitute for good, safe working

conditions and intelligent, right working habits of personnel; but its
usage is a must
Use the protective equipments properly wherever necessary. Select the suitable
protective equipment for the purpose. The person wearing the equipment must be
familiar with the method of its usage. Protective equipments must be kept in good
working conditions (with frequent inspection and immediate repairs if necessary).
Protective equipments must be available at specified locations.
Respiratory protection: - Used against harmful gases.

Note: Fumes of HCl, H2SO4, Cl2, and NH3 can burn the other parts of body.
Respiratory protection only is not insufficient.
Oxygen supplied masks:
These masks give full protection regardless of the concentration of toxic gases
(which are not otherwise harmful). Their disadvantages are that they can be used
for a limited time only and require skill in handling.
Fresh Air masks (Masks with fresh air supply line)
These are full face masks into which fresh air is blown through a long hose with
pressure regulation. The mask can be used in any concentration of toxic gases
(which are not otherwise harmful). This can be used for a long time.
22
Disadvantage:
 A long length of hose if not properly handled gives rise to dangerous situation
also it needs a second person to operate the blower.
 In case of supply air from the running machine which fails, a stand by supply
from compressed air cylinder must be made.
Canister type Masks

Full face mask equipped with a special cartridge containing chemicals removes the
toxic components from the air breathed through the Canister. Different cartridges
are available for various kinds of toxic gases. This type can only be used when the
concentration of toxic gas is lower than for what is specified, and the concentration
of air breathed in through cartridge should contain more than 18% oxygen by
volume.
Disadvantage is that the cartridge capacity is relatively small. Before the chemical
in the cartridge is exhausted and the toxic gas breaks through, the wearer must
return to the safe atmosphere. A person vigilant from outside must caution the
elapsed time to ensure safe return.
- The resistance of the Canister cartridge makes breathing difficult when manual
exertion is there.
Clothing: - Avoid using polyester clothing in plant areas, especially while working in
Furnace areas and hot hydrocarbon areas. Use cotton clothes fully cuffed.
Hand protection: Use appropriate hand gloves for any kind of operation in plant area
(e.g. asbestos gloves: in steam/hot service. PVC/Rubber gloves: for acid/alkali
handling: Leather gloves: for Hydrocarbons).
Foot Protection: - Safety shoes of approved standards like ISI with built in steel
toe-caps to be worn. When necessary boots of special chemical resistant material
must be worn (for e.g. handling acid spills, alkalis etc.).
Protective suit: - These are required against splash of chemicals.
Head protection: - Safety helmets of approved standards must be worn around the
unit at all times.
Showers, eye irrigators: - Meant for washing/flushing in case of splashing of
chemicals; should not be misused.
Goggles: While lighting up burners, inspection of furnace peep doors etc.
Ear mufflers: For areas with higher noise levels (e.g. compressors)
4.2 Mechanical, Electrical and Plant Operation Hazards:-

 Mechanical Hazards, Plant Maintenance
Good housekeeping on the plant is essential to safety. Spillages, leaks must be

avoided. Any leak particularly where inflammable or toxic materials is involved
should be promptly attended to. Unusual noises or conditions of running equipments
should be reported and attended promptly.
Use the right tool required for the job.
 Non sparking tools must be used where specified (where possible presence
of flammable gases is there).
 Take care of hazards present in certain rotating machinery for example:
 Guards around couplers, fans etc.
 Nitrogen purge to crank cases of Hydrogen compressors.
23
Relief valves should be serviced, inspected regularly but not to be tampered with.
Trip system/safety devices are connected to the static and running equipments to
ensure protection against operational abnormalities and mechanical faults, like
extreme process conditions, high vibrations, bearing failures etc. Service/calibrate
these devices regularly; make sure that they are in service.
Air must not be admitted into the plant except as laid down in the operating
instructions, to avoid risk of overheating reduced catalyst and explosion in the
system.
Insulation: Although from process point of view, the insulation of some hot
equipment and piping may not be required or economically justified, it has to be done
for personnel protection, especially in areas where frequent travel of operating
staffs or other concerned persons are envisaged.
 Electrical Hazards:
Electrical equipments in particular should be opened by electrical staff holding valid

permits only even when properly isolated. Use of sparking equipments, welding or
Oxy-acetylene cutters within B/L should be subject to permits.
 Static Electricity:
o Static electricity is generated in the flowing fluid as the pipe gets
oppositely charged.
o In the Petrochemical industry, the flow, transportation, handling of such
fluids as:-
- Hydrocarbons
- Paints
- Sprayed water
- Sand blasting.
generates dangerous static electrical charges.
o Static electricity cannot be avoided in practice, but charge build up can and
should be avoided.
o Electrostatic charge build-up can be prevented by grounding feed pipes
and the receiving tank.
o Check that grounding devices are always in good condition with respect
both to vehicles and fixed facilities/piping. (Ex. Unloading of chemicals
from the tankers).
o All contact metal parts should be very clean and strongly connected.
Vehicle Power Point should be electrically connected to tanks.
o Personnel should not forget to turn on the switching device after fitting the
vehicle connection.
o Never use a water or Steam hose for a non-degassed tank without the hose
being connected electrically to the grounded tank.
o The fixed earth connections should be periodically checked and resistance
measured.
o Any observed damage should be immediately reported.
 Lightning etc during thunder storm.
 Above ground tanks and containers are particularly exposed to lightning

as their steel made outer shell protrudes from the ground.
24
 Not only should lightning be taken into account, but also the electrostatic charges
generated by storms in the atmosphere.
 During an electrical storm (thundering and lightning) the following precautions
should be taken;
a) Stop hydrocarbon loading and unloading
b) Shut off carefully all fixed and portable storage facilities and stop manual
outage.
c) Reduce non essential transfer operations.
d) Do not stand on tanks or high structures.
Stop working on electric lines, telephone lines, steel structures, downpipes, and
towers and on all metal parts that may conduct lightning discharge.
 Electrical Equipment – Plant:

Personnel likely to work with electrical and allied equipment (measuring instruments
pumps, fans) should be admittedly skilled and proficient. They should be familiar
with the equipment concerned, with the safety instructions applicable to electric
system construction, operating and maintenance works, with the safety and
emergency regulations specific to their profession and plant.
 It is essential that great care is taken to understand and follow the plant
safety directions. As a rule, no work should be carried out with the power
supply on unless there is no other possibility to do it. If in doubt, provide
the following materials equipment and precautions;
o Insulating stool
o Insulated mat
o Individual tools with insulating handles
o Insulating sole boots or ankle boots
o Protective helmet
o Insulating gauntlets for working with conductors
o Shutting off switch or breaker. In case this is not possible, lock out
the, breaker and post a notice. A pair of cable-shears, a collapsible
pole and a safety belt should be added to individual’s equipment for
overhead works.
 First Aid to Victims of Electric Shock

o If possible, switch off the current.
o Take the victim away from the energized equipment. Rescuer should be
protected.
o Should rescuer not be sure current is off, he must take insulating
precautions using stools, gloves, poles.
o Operate always with one hand only.
o Unfasten victim's clothes and give at once artificial respiration. Unless
being in too small a space, do not remove the victim to another location.
o Take prompt action as the victim's life is in jeopardy.
o Call First Aid Centre or hospital immediately.
o Do not stop manual resuscitation until a mechanical resuscita tor can be

used.
25
4.3. Plant Operational – Hazards

 Attention to Operating Procedures:-
Particular care should be taken to observe the operating procedures and precautions
described in other section of his manual. Safe plant operation, ignition of burners
etc. should be reviewed carefully to ensure unsafe situations are not allowed to
develop.
 Bypassing of Safety/Critical Systems
The maintenance and consistent use of emergency shutdown and/or other safety
systems and devices is necessary to protect personnel and equipment. Bypassing
any of these systems or taking them out of service without proper communication
and follow up could result in serious consequences to personnel and equipment.
However, certain conditions do necessitate the by-passing of a trip system. Should
these conditions arise and it becomes necessary to defeat a safety system.
1. Safety systems and devices should not be Bypassed or disconnected without
the shift supervisor’s approval.
2. The shift supervisor must approve the Bypass or disconnection of any safety
system and must notify the Operations Manager.
3. A written description must promptly be made to the Operations Manager,
explaining the system in defeat.
4. Once the condition is restored to "normal', the report should be filed for
historical records.
5. "Trip Bypass Register" should be kept in the shift supervisor's office and
should be used to record the status of bypassed/ disconnected/ shutdown
safety systems. Information recorded should include, but not limited to:
6. Identification/location of bypassed system or device.
7. Name of shift supervisor authorizing the defeat.
8. Time and date of trip bypass.
9. Estimated time or date of reactivation or return to service.
10. Reason for bypassing.
11. The purpose of the "Trip Bypass Register" is to ensure that all technicians,
supervisors and management are aware of the bypassed system or systems
and are sensitive the impact such action may have on the current operating
conditions.
12 The "Trip Bypass Register" should be reviewed by technicians. Supervisors
and management on a daily basis and monitored until the trip bypass is
removed.
 Training:-
It is essential that personnel are trained positively “To Stop Accidents”. Almost all
accidents can be prevented by systematic consideration of what can happen followed
by development and implementation of suitable training procedures.
All concerned with operation of the plant should be thoroughly aware of potential
hazards and be capable of initiating the steps necessary to overcome them without
delay.
Staff must be familiar with hazards and safe handling procedure associated with the
various chemicals at the plant.
4.4 Fire Hazards:
26
 Fire Extinguishers: - In many cases, the operator can prevent a large fire by
extinguishing when it is small (before it gets out of control). Adequate
knowledge of the types of fire extinguishers and their usage is a must.
Water:-For extinguishing fires on paper, wood and such material.
a) For cooling tanks/vessels etc.,
b) As fog to protect personnel against radiant heat.
c) As fog to extinguish small hydrocarbon fires.
Steam:-
a) For Hydrocarbon fires in trenches and similar confined spaces.
b) For extinguishing small flames; e.g.: on leaking flanges.
Foam:-
a) For oil fires.
b) The above extinguishing agents should never be used on electrical
equipments.
Carbon Dioxide:-
a. On small oil fires
b. On small gas fires in confined space.
Dry Powder:-
a) On all small oil and gas fires for extinguishing a fire. In electrical
equipment (consult electrical personnel, confirm power isolation to the
equipment), use only Carbon Dioxide and dry powder extinguishers.
b) Large gas fires should not be extinguished until the supply of gas to
the flames has been shut off, preventing re-ignition of unburned gases.
c) In case of such fires it is necessary to protect personnel and
surrounding equipments. Asbestos blankets are used to extinguish a
persons' burning cloth. Safety hats, gloves, adequate supply of
protective equipments, heat shield, suits against radiation are
necessary. Surrounding equipments like tanks to be kept cool with
judicious application of water.
All operators must be thoroughly familiar with the location of the portable fire
extinguishers, Steam hoses, hydrants and water hoses and the protective
equipments. Each operator must know when and how to use the different
extinguishers.
 In case of Fire:
Hydrogen, hydrocarbon gases constitute a fire hazard if they come in contact with
air/oxygen. When the temperatures of leaking gases are above that of auto ignition,
fire may break out without an ignition source.
Auto Ignition Temperature:-
Hydrogen 565 oC
Methane 537 oC
Carbon Monoxide 550 oC
Natural Gas 537 oC
Naphtha 230- 237 oC
Kerosene 210 °C
Gas Oil 338 °C
It is the experience that small fires occur occasionally (once in a while).

These have to be promptly dealt with to minimize the hazard.
27
a. Inform the Fire control room about the fire very clearly, disclosing the
identity of person, exact location and nature of fire.
b. Buddy system' (minimum two persons have to be there for fighting fire)
for fire fighting has to be strictly followed. Till additional assistance
arrives, fight the fire with suitable extinguisher.
 In case of large Fires:-

Over all efforts fall into these distinct broad activities which have to be carried out
with perfect co-ordination.
a) Isolation of fire, orderly shutdown of the unit.
b) Fire fighting
c) Rescue of affected personnel.
The general procedure from the point of view of operating staff shall be as follows.
(i) Inform the Fire control room clearly, activate the fire alarm.
(ii) Shut off flow of Fuel Gas/Fuel Oil to burners.
(iii) Stop the flow of Gas/HC streams to the equipment that is on fire, and
depressurise. But keep a slight positive pressure on the equipment. Where possible
put Steam in.
(iv) Follow as much as possible emergency shutdown procedure. Do not allow
process parameters to go beyond control which would aggravate the situation.
(v) A serious gas leak from the equipment should be allowed to burn, under control,
while the supply Gas/HC is blocked off. If the flame is extinguished while the gas
leak continues, the gas may spread as an explosive cloud with potential danger of
being re ignited elsewhere.
(vi) A way to extinguish a fire produced by a line leak is to inject Steam or Nitrogen
into the line through a temporary connection from the nearest possible location, after
cutting off the flammable fluid/gas.
(vii) The use of water directly on the fire is a matter of judgment.
(viii) Persons not actually participating in the operations of the unit or in the fire
fighting are not allowed in the process area.
Main access routes should always be kept clear to ensure personnel can get
away safely from any unexpected hazard. Discipline regarding `No Smoking'
areas should be strictly followed. Emergency escape root to be clearly
marked.
4.5 Hazardous Materials/Chemical Handling
The staff must be familiar with hazards and safe handling procedure associated with
the various gases and chemicals encountered in the plant.
 Hydrogen
General Information
Formula : H2
Description : Odourless, colourless gas considerably lighter than air
Molecular Wt. : 2
Atm. Vapour density : 0.069 (with respect to air taken as 1)
Hazards
28
Flammability : Highly dangerous when exposed to heat flame or sparks

Explosion : Highly dangerous, explosive range with air, 4-75%
Health : Not a toxic gas but does not support life i.e. asphyx-
iation as the oxygen level falls below 18%.
Countermeasures
Personal Precautions:-
(i) Leaks of gas liable to contain H 2 should be reported at once, all personnel to be
kept clear of the contaminated area.
(ii) Personnel must avoid inhaling gas believed to contain H 2 whether from gas
samples or leaks.
(iii) Do not work in areas where contamination by leakage is possible without
separate fresh safe air supply.
(iv) If vessels, columns or other enclosed spaces that are subject to Hydrogen are
to be worked in, they must be positively isolated from further sources of gas,
thoroughly purged with inerts refilled with air and tested to ensure that H 2 is absent
before work begins. An air stream should be maintained while work is in progress,
together with constant supervision of person(s) involved.
Protective Equipment:-
Air supplied mask equipped with full face pieces, must be worn for protection where
an oxygen deficiency - less than 15 percent by volume, or a concentration of
a harmful gas may be encountered. (Dragger tubes are very useful for rapid
testing).
Approved industrial canister type gas masks fitted with the proper canister for
absorbing Hydrogen may be used if the oxygen concentration is not less than 18%.
First Aid Training:
Operating Personnel should be given full training to ensure First aid can be readily
applied if required. The principles are generally as follows;
(i) Remove the victim from the scene of the accident as the surrounding air is still
likely to be contaminated with Hydrogen. Resources should be properly protected
and provided with a lifeline.
(ii) Examine mouth for false teeth and chewing gum and remove if present.
(iii) Apply artificial respiration if the breathing appears to be shallow or stopped.
The first few minutes after the discovery of an unconscious, gassed person are
vitally important and artificial respiration must be resorted immediately and must not
be delayed while awaiting the arrival of stretcher or other equipment. Of the several
methods of applying artificial respiration, the mouth to mouth method of positive
pressure is considered to be the most efficient for general purposes.
(iv) Keep the victim warm with the head in a low position. Once the breathing has
been properly restored further attention can be directed to the adequate treatment
of those symptoms indicating shock. These are usually pallor, cold, clammy skin and
shivering. Absolute rest and protection from cold are the first essentials and the
victims should be kept in position with the head kept low and turned to one side,
so as to allow as much of the blood as possible to reach the brain and support
vital functions.
The conscious or semi-conscious person should not be walked about because any
muscular activity involved may lead to heart failure.
(v) Administering of Oxygen increases the rate at which Hydrogen can be
eliminated. If five percent of Carbon dioxide is added to the supply of Oxygen it
will tend to stimulate the respiratory centre of the brain and bring about an
increase in the depth of breathing. Oxygen without Carbon dioxide is recommended
29
when it is to be given under positive pressure. Carbon dioxide alone cannot serve
these requirements and must not be used.
Oxygen should only be administered by trained personnel.
(vi) Give the patient plenty of hot drink. When the patient is able to swallow, hot
coffee or tea with plenty of sugar BUT NO MILK, should be given freely. To begin
with however, drink should be given in small quantities. DO NOT GIVE ALCOHOL.
(vii) Maintain a constant watch over more serious cases. Pending transfer to
hospital, careful watch must be maintained over the patient in all serious cases
because of the tendency to relapse. Should breathing become shallow or very slow
or appear to have ceased, artificial respiration should be given and immediate
administration of oxygen is recommended.
(viii) Do not allow patient to suffer any form of exertion
 Hydrogen Sulphide
General Information:
Formula : H2S
Description : Colourless gas, denser than air with an offensive odour
commonly referred to as odour of rotten eggs.
Molecular Wt. : 34
Boiling Point : - 60oC
Density : 1.19 (with respect to air)
Hazards:
Flammability : Burns in air releasing considerable quantities of heat to form
Sulphur dioxide and water. Reacts violently with any oxidants.
Explosion : Forms explosive mixtures with air.
Health : Hydrogen Sulphide, even in low concentrations, acts, as an
irritant to the eyes and respiratory tract. Increased
concentrations become progressively more harmful until high
concentrations, if inhaled cause rapid death.
This gas kills the sense of smell. Do not depend on odour to detect presence
of gas.
Counter Measures
Personal Precaution:
(I) Leaks of gas liable to contain H 2S should be reported at once, all personnel being
kept clear of the contaminated areas.
(ii) Personnel must avoid inhaling gas believed to contain H 2S, whether from gas
samples or leaks.
(iii) Do not work in areas where contamination by leakage is possible, without
If vessels, columns or other enclosed spaces that are subject to Hydrogen Sulphide
are to be worked in, they must be positively isolated from further sources of gas,
thoroughly purged with inerts, refilled with air and tested to ensure H 2S is absent,
before work begins. An air stream should be maintained whist work is in progress,
together with constant supervision of person(s) involved.
30
Air supplied masks, equipped with full face pieces, must be worn for protection
where an oxygen deficiency (less than 18% by volume) or a concentration of a
harmful gas may be encountered (Dragger tubes are very useful for rapid testing).
Approved industrial canister type masks, fitted with the proper canister for
absorbing Hydrogen sulphide may be used if the oxygen concentration is not less
than 18%.
First Aid Training
Operating personnel should be given full training to ensure First Aid can be readily
applied if required. The principle are generally as follows;-
likely to be contaminated with Hydrogen sulphide. Rescuers should be properly
protected and provided with a lifeline.
The first few minutes after the discovery of an unconscious, gassed person are
vitally important and artificial respiration must be resorted to immediately and must
not be delayed awaiting the arrival of a stretcher, blanket or other equipment. Of
the several methods of applying artificial respiration, the mouth-to-mouth method is
considered to be the most efficient for general purposes.
(iv) Keep the victim warm with the head in a low position.
Once the breathing has been properly resorted, further attention can be directed to
the adequate treatment of those symptoms indicating shock. These are usually
pallor, cold, clammy skin and shivering. Absolute rest and protection from cold are
the first essentials and the victim should be kept in a position with the head kept
low and turned to one side, so as to allow as much of the blood as possible to
reach the brain and support the vital functions.
The conscious or semi conscious person should not be walked about because any
muscular activity involved may lead to heart failure.
(v) Administering of oxygen increases the rate at which Hydrogen Sulphide can be
eliminated. If 5% of Carbon Dioxide is added to the supply of Oxygen, it will tend to
stimulate the respiratory centre of the brain and bring about an increase in the depth
of breathing. Oxygen without Carbon Dioxide is recommended when it is given
under positive pressure.
Carbon Dioxide alone cannot serve these requirements and must not be used.
(vi) Give the patient plenty of hot drink, when the patient is able to swallow, coffee
or tea should be given freely, with plenty of sugar BUT NOT MILK. To begin with
however, drink should be given in small quantities. DO NOT GIVE ALCOHOL.
(vii) Hydrogen Sulphide causes irritation to the eyes which may become painful, in
which case:-
1. Keep the patient in a darkened room.
2. Apply iced compress to the eyes.
3. Put ice cap on forehead.
4. Send for physician.
5. Do not allow patient to suffer any form of exertion
 Carbon Monoxide
General Information
Formula : CO
Description : Colourless, odourless gas
31
Molecular Weight : 28.01

Melting Point : - 191.3° C
Boiling Point : - 207 °C
Atmospheric Vapour Density : - 0.96 (Air = 1.0)
Hazards.
Flammability: Dangerous when exposed to flame, Does not promote spontaneous
heating.
Explosion: Severe when exposed to heat or flame. Explosive range with air is 12.5
- 74.2 %. CO interferes with the normal transportation of Oxygen by the blood to
body. In general, loss of energy occurs, often resulting in the individual being
unable to use his legs to escape the dangerous atmosphere even though fully con-
scious.
Countermeasures
1. Personnel Precautions:
(i) Leaks of gas liable to contain CO should be reported at once, all personnel being
kept clear of the contaminated area.
(ii) Personnel must avoid inhaling gas believed to contain CO, whether from gas
samples or leaks.
(iii) Do not work in area where contamination by leakage is possible, without
(iv) If vessels, columns or other enclosed spaces that are subject to Carbon
Monoxide are to be worked in, they must be positively isolated from further sources
of gas, thoroughly purged with inerts, refilled with air and tested to ensure CO is
absent before work begins. An air Stream should be maintained whilst work is in
progress, together with constant supervision of person(s) involved.
Protective Equipment
Air supplied masks, equipped with full face pieces, must be worn for protection
where an Oxygen deficiency (less than 18% percent by volume), or a concentration
of a harmful gas may be encountered (Dragger tubes are very useful for rapid
testing).
Approved industrial canister type gas masks, fitted with the proper canister for
absorbing Carbon Monoxide may be used if the oxygen concentration is not less than
18%.
First Aid Training
Operating Personnel should be given full training to ensure First Aid can be readily
applied if required. The principles are generally as follows:
likely to be contaminated with Carbon Monoxide. Rescuer should be properly
protected and provided with a life line.
The few minutes after the discovery of an unconscious, gassed person are vitally
important and artificial respiration must be restored to immediately and must not be
delayed while awaiting the arrival of a stretcher, blanket or other equipment. Of the
several methods of applying artificial respiration, the mouth-to-mouth method is
considered to be the most efficient for general purposes.
(iv) Keep the victim warm with the head in a low position.
32
Once the breathing has been properly restored, attention can be directed to the
adequate treatment of those symptoms indicating shock. These are usually pallor,
cold, clammy skin and shivering. Absolute rest and protection from cold are the first
essentials and the victim should be kept in position with the head kept low and
turned to one side, so as to allow as much of the blood as possible to reach the
brain and support the vital functions.
The conscious or semi-conscious person should not be walked about because the
muscular actively involved may lead to heart failure.
(v) Administering of Oxygen increases the rate at which Carbon Monoxide can be
eliminated. If 5% of Carbon Dioxide is added to the supply of Oxygen, it will tend to
stimulate the respiratory centre of the brain and bring about an increase in the depth
of breathing. Oxygen without Carbon Dioxide is recommended when it is to be given
under positive pressure.
Carbon Dioxide alone cannot serve these requirements and must not be used.
Oxygen should only be administered by trained personnel.
(vi) Give the patient plenty of hot drink. When the patient is able to swallow, hot
coffee or tea should be given freely, with plenty of sugar BUT NOT MILK. DO NOT
GIVE ALCOHOL.
(vii) Maintain a constant watch over more serious cases. Pending transfer to
hospital, careful watch must be maintained over the patient in all serious cases,
because of the tendency to relapse. Should breathing become shallow or very slow
or appear to cease, artificial respiration and immediate administration of Oxygen
should be begun or recommended.
(viii) Do not allow patient to suffer any form of exertion.
 Nitrogen, Carbon Dioxide, Argon and other simple Asphyxiant
General Information
Nitrogen
Formula : N2
Description : colourless gas
Molecular Wt : 28
Atmospheric Vapour Density : 0.97
This gas is almost universally used in industry as an inert atmosphere and is one of
the most commonly encountered substances. Dispersal of local high concentration is
hindered because the vapour density is very similar to that of air.
Carbon Dioxide
Formula : CO2
Description : Colourless, Odourless gas,
Molecular Wt : 44
Atmospheric vapour density : 1.53
Commonly used as an inert gas, in the soft drinks & fire fighting equipments. Liable
to collect in pits and low areas as it is denser than air.
Argon
Formula : Ar
Description : Colourless, Odourless gas,
Molecular Wt : 40
33
Atmospheric Vapour Density : 1.38

Commonly used as an inert gas blanket when welding. Liable to collect in pits & low
areas as it is denser than air.
Hazards
Simple Asphyxiciants do not support combustion nor do they burn, thus there are no
flammability or explosion hazards.
Health
Classified as simple Asphyxiciants with no specific toxic effects. But they act by
excluding Oxygen. The first symptoms produced by simple as physician gases are
rapid respirations and air hunger. Mental alertness is diminished and muscular co-
ordination is impaired. Later, judgment becomes faulty and all sensations are
depressed. Emotional instability often results and fatigue occurs rapidly.
The major hazard with these gases therefore arises from a false sense of security
associated with their inert non poisonous nature, and the danger of asphyxiciantion
is readily overlooked.
Countermeasures
Personal Precautions:-
(i) All purging operations using these gases should be logged and warning notices
posted in the vicinity of the operation.
(ii) Personnel must avoid inhaling air enriched with these gases and should use a
breathing air/oxygen apparatus if local concentrations are suspected or possible.
(iii) Where access to vessels filled with any of these gases is required, for
inspection or maintenance, either the proper breathing apparatus must be used or
the vessel must be air purged. In both cases it is essential to maintain close
supervision of the men involved.
(iv) Adequate provision must be made for retrieving the man in the event of his
being overcome. A lifeline tied round his waist with sufficient manpower to haul him
out quickly or men with breathing apparatus standing by to rescue him/her are
necessary.
(v) When the vessel is to be air purged the following procedures should be used.
The vessel must be isolated from all possible sources of supply of asphyxiant and
depressurised, where possible via a local high vent. Then pressurise the vessel with
air to a minimum of 2 Kg/cm2, depressurise and repeat the process, not less than
two times. The atmosphere inside the vessel should then be tested for the presence
of oxygen. If the vessel atmosphere is safe (Oxygen not less than 20%), work can
commence (continuous slow air purge is advisable).
(vi) Particular danger arises because, within seconds of breathing simple
asphyiants a feeling of well being and elation is induced such that the victim
has no reflex to fight for breath but simply feels good, becomes sleepy and
then collapses.
(i) Air supplied masks, equipped with full face pieces, and must be worn for
protection where an oxygen deficiency - less than 18% by volume - may be
encountered. O2 concentration can easily be rapidly measured using standard
industrial equipment.
(ii) Gas/Canister masks must not be used - they are completely in effective.
First Aid Training:-
34
Operating personnel should be given full training to ensure first Aid can be readily
applied if required. The principles are generally as follows:-
(i) Remove the victim from the scene of the accident. Rescuers should use breathing
apparatus and provided with a lifeline.
The first few minutes after the discovery of an unconscious gassed person are
vitally important and artificial respiration must be resorted to immediately and must
not be delayed while awaiting the arrival of a stretcher and other equipment. Of the
several methods of applying artificial respiration, the mouth-to-mouth method of
positive pressure is considered to be the most efficient for general purposes.
Keep the victim warm with the head in a low position. Once the breathing has been
properly restored, further attention can be directed to the adequate treatment of
those symptoms indicating shock. These are usually pallor, cold, clammy skin and
shivering. Absolute rest and protection from cold are the first essentials and the
victim should be kept in position with the head kept low and turned to one side, so
as to allow as much of the blood as possible to reach the brain and support the vital
functions.
The conscious or semi-conscious person should not be walked because any
muscular activity may lead to heart failure.
Administering Oxygen increases the rate at which simple asphyxiant can be
eliminated but such treatment must be carried out by trained personnel.
Give the patient plenty of hot drink, when the patient is able to swallow, hot coffee
or tea with plenty of sugar but not milk should be given freely. To begin with
however a drink should be given in small quantities. DO NOT GIVE ALCOHOL.
Maintain a constant watch over more serious cases. Pending transfer to hospital,
careful watch should be maintained over the patient because of the tendency to
relapse. Should breathing become shallow or very slow or appear to have ceased,
artificial respiration should be begun and immediate administration of oxygen should
be recommenced. Do not allow patient to suffer any form of exertion- Case
Histories:
Previous occurrences of fatalities or near fatalities have been reported by several
organizations. One such incidence -
One man entered the vessel containing Nitrogen wearing an air mask but for some
reason took it off and promptly collapsed. The second man outside the vessel, who
was meant for rescue operation, entered the vessel to rescue his colleague without
raising the alarm and not wearing an air mask himself. He also collapsed and died.
 Hydro treating catalyst:
If it proves necessary to handle the catalyst, use the protective equipment and wear
an air or oxygen mask because of the possible presence of traces of carbonyls or
hydro carbonyls which are toxic at concentrations of 0.001 ppm at a contact time
lasting 8 hours.
This toxicity can be compared with the minimum unsafe concentrations of 20 ppm
for H2S or 100 ppm for CO, i.e., it is much more dangerous. Used (unregenerated)
catalyst is pyrophoric and has to be handled under nitrogen blanket conditions.
Safety regulations for reactor entry must be strictly enforced.
35
 Carbonyls
Formed by combining the CO group and metal, in particular Ni, Fe, Co, Mo, under
certain operating conditions, in presence of carbon monoxide.
During regeneration step of catalyst it is possible to produce small quantities of
metal carbonyl, but exact quantities cannot be precised. DHT catalyst can contain
traces of nickel, cobalt or molybdenum carbonyl.
a) Physical properties
Some of the carbonyls, nickel in particular, are very toxic, so their formation must
be avoided in the interest of safety. Whenever workers are going to enter or open a
catalytic reactor, stringent precautions should be followed to assure that carbonyls
are not present. Even in closed systems where there is no safety hazard, carbonyl
formation should be prevented, since it may remove metal from the catalyst and
cause loss of activity.
The toxicity of carbonyls depends in part, but not always, on their easy
decomposition which releases carbon monoxide.
Symptoms are due in part to CO and in part to direct irritating action of the carbonyl.
Concentration as low as 1 ppb is toxic for an exposure time of 8 hours. They react
with water or steam to produce toxic or flammable vapours and can react vigorously
with oxidizing materials.
b) Detection of carbonyls
Infrared spectrometry can be used to detect carbonyls in the range of 1 to 10 ppb.
The flame of a Bunsen burner or alcohol lamp can be used as a simple and effective
test for carbonyls; metal carbonyls will impart a readily observable luminosity to
flames, even if the concentration of the
carbonyl is as low as 1 ppm.
c) Personnel protection
If it is necessary for the personnel to enter a reactor where the presence of nickel
carbonyl is suspected, they should be equipped with self-contained air masks and
skin protection.
Pyrophoric materials – iron sulphide:

Used catalyst, which will be coated with iron sulphide, is pyrophoric and has to be
handled under nitrogen blanket conditions. Due to the presence of H 2S, iron sulphide
is also present in other parts of the unit. This substance is subject to ignition when
exposed to air. Any vessel, filter, screen where iron sulphide is collected should
kept water-wet until cleaned or
safely disposed of.
Note: While handling chemicals, appropriate PPEs should be used based on

MSDS (HAZOP recommendation no. 207).
36
4.6 Material safety data sheet (MSDS)
 Catalyst-HR 548- specification & properties
Use of the substance/preparation:

Refinery catalyst for treating petroleum cuts. Alumina impregnated with molybdenum
and nickel oxides.
Hazardous Identification:
 This product is not classed as flammable. Refer to the recommendations
regarding the other products present on the site
 Possibility of serious noxious effects in the event of repeated or prolonged
exposure and by inhalation and swallowing.
 Possibility of irritation to the eyes and by inhalation.
 Possibility of skin sensitisation. The preparation may also irritate the skin and
prolonged contact may aggravate this effect.
 Possibility of category one carcinogenic effects due to inhalation.
Preparation classification:
 May cause sensitisation by skin contact.
 Irritating to eyes and respiratory system.
 Harmful: danger of serious damage to health by prolonged exposure through
inhalation and if swallowed.
 May cause cancer by inhalation.
 For professional use only.
Other data:
 Avoid the formation or spread of dust in the atmosphere
Composition/information of ingredients:
Hazardous substances present on their own: (present in the preparation at a
sufficient concentration to give it the toxicological characteristics it would have in a
100% pure state)
Nickel monoxide : 2.5 <= x % < 10
Molybdenum Trioxide : 10 <= x % < 25
Other substances with occupational exposure limits:

Alumina : 50 <= x % < 100
First Aid Measures:

As a general rule, in case of doubt or if symptoms persist, always call a doctor.
NEVER induce swallowing in an unconscious person.
37
In the event of exposure by inhalation:

 In the event of inhalation, move the patient into the fresh air and keep him/her
warm and still.
 If breathing is irregular or has stopped, effect mouth-to-mouth resuscitation
and call a doctor.
 Do not give the patient anything orally.
 If the person is unconscious, place in the recovery position and call an
ambulance.
In the event of splashes or contact with eyes:

 IMMEDIATELY rinse with plenty of water for a prolonged period, (at least 15
minutes) by keeping the eyes wide open.
 If irritation persists, consult an eye specialist.
In the event of splashes or contact with skin:

 Rinse with plenty of water.
In the event of swallowing:

 In the event of swallowing, if the quantity is small (no more than one
mouthful), rinse the mouth with water and consult a doctor.
 Call a doctor immediately and show him the label.
Fire-Fighting Measures:
Suitable extinguishing media:
 All extinguishing agents can be used.
Extinguishing media which must not be used for safety reasons:

 If there is a fire extinguish by using suitable extinguishing agents.
Accidental Release Measures:

Personal precautions:
 Avoid inhaling dust.
 Consult the safety measures listed under headings 7 and 8.
 If a large quantity has been spilt, evacuate all personnel and only allow
intervention by trained operators equipped with safety apparatus.
Environmental precautions:
 Prevent any material from entering drains or waterways.
 Use drums to dispose of waste recovered in accordance with applicable
regulations.
 If the product contaminates waterways, rivers or drains, alert the relevant
authorities in accordance with statutory procedures.
Methods for cleaning up:

 Sweep up or vacuum up the product.
 If necessary, wash with water following recovery.
Handling & Storage:
38
 The regulations relating to storage premises apply to workshops where the

product is handled.
 Anyone with a history of skin sensitisation must on no account handle such
products
Handling:
 Handle in well-ventilated areas.
 Does not require any specific or particular measures.
 Avoid the formation or spread of dust in the atmosphere.
Fire prevention:
 Prevent access by unauthorised personnel.
Recommended equipment and procedures:
 For personal safety, see §8.
 Observe precautions stated on label and also industrial safety regulations
 Avoid exposure - obtain special instructions before use.
 Avoid inhaling vapours. Carry out any industrial operation which may give rise
to this in a sealed apparatus.
 In all cases, recover emissions at source
 Provide vapour extraction at the emission source and also general ventilation
of the premises
 Also provide breathing apparatus for certain short tasks of an exceptional
nature and for emergency interventions
 Avoid contact of product with the skin and eyes
Prohibited equipment and procedures:
 Smoking, eating and drinking are prohibited in premises where the
preparation is used
 Never open the packages under pressure
Storage:
 Keep the container tightly closed in a dry place.
Exposure Controls/Personal Protection:

 Use personal protection equipment as per Directive 89/686/EEC.
products.
Technical measures:
 Ensure adequate ventilation, if possible with extractor fans at work posts and
appropriate general extraction.
 Check the atmosphere periodically.
 If this ventilation is insufficient to maintain the concentration of vapours
below the exposure limits, wear breathing apparatus.
Respiratory protection:
 With this preparation, avoid in particular any inhalation of vapors.
 If dust is generated:
 Respiratory protective device with a particle filter.
Hand protection:
 Appropriate gloves.
Eye and face protection:
 Avoid contact with eyes.
39
 Wear safety goggles.

 Provide eye washes in workshops where the product is constantly handled
Skin protection:
 Protective clothing with elasticated cuffs and closed neck.
Typical Properties:
 Nickel and molybdenum oxides on very high purity alumina Trilobe
extrudates
Nickel (NiO) : 4.5 wt%
Molybdenum (MoO3) : 21 wt%
Surface area : 205 M2/g
Total pore volume : 0.46 Cm3/g
Diameter : 1.2 1.6 2.5 mm
Sock loading density : 0.66 0.69 0.70 kg/l
Dense loading density : 0.78 0.80 0.81 kg/l
Bulk crushing strength : 1.49 MPa
Physical state : solid in granules
Melting point/melting range: 2000 °C.
Stability & Reactivity:

Materials to avoid:
Under certain conditions, it reacts with carbon monoxide, forming nickel carbonyl
Ni(CO)4, which is a very toxic gas.
Toxicological Information
 It is generally agreed that substances contained are likely to cause serious
irritation of the respiratory system and, when applied to the eye of an animal,
the appearance of major lesions which persist for at least twenty-four hours.
 It is generally agreed that substances contained are likely to cause, among
certain predisposed subjects, a sensitisation reaction by cutaneous route
 It is generally agreed that substances contained are likely to cause category 1
carcinogenic effects on inhalation
Ecological Information
 No ecological data on the product itself is available.
 The product must not be allowed to run into drains or waterways.
Mobility:
 Slightly soluble product, readily forms deposits.
Persistence and degradability:
 Inert mineral product. Not degradable.
Disposal Considerations
 Do not pour into drains or waterways.
Waste:
 Recycle or dispose of waste in compliance with current legislation, preferably
via a certified collector or company.
 Do not contaminate the ground or water with waste; do not dispose of waste
into the environment.
40
 The exhausted catalysts may have different risks and properties compared to
the original product. This safety data sheet is not applicable to exhausted
catalysts.
Soiled packaging:
 Empty container completely. Keep label(s) on container.
More Information on HR 548 Catalysts:

Specification & Properties
Manufacturer : AXENS IFP Group Technologies
Product Name : HR 548
Size (1) : 1.6 mm
Loading type : Dense
Volume (2) : 344.643 m3
Estimated density : 800 kg/m3
Estimated weight : 275 714 kg
HR 548 is the latest generation of NiMo type catalysts manufactured by Axens. It

presents very high denitrification and aromatic hydrogenation activities, as well as a
superior desulfurization activity.
These features are particularly interesting in the treatment of feedstocks originated
from thermal and catalytic conversion processes as well as for FCC feed pre-
treatment. HR 548 is a very illustrative example of the Avanced Catalyst
Engineering knowhow of Axens. It can be used in association with other NiMo type
or CoMo type catalysts where Specific objectives are required. HR 548 is delivered
under oxide form. It can be sulfided in-situ by injection of sulphur compound. HR
548 is available with a diameter of 1.2 mm or 1.6 mm or 2.5 mm.
 Catalyst ACT 069- specification & properties

Refinery catalyst for treating petroleum cuts. Ceramic based on alumina and silica.
Hazards Identification
This product is not classed as flammable. Refer to the recommendations regarding
the other products present on the site
This preparation is not classed as hazardous to health by directive 1999/45/EC.
Composition/Information on Ingredients
Hazardous substances present on their own:
(present in the preparation at a sufficient concentration to give it the toxicological
characteristics it would have in a 100% pure state)
41
This preparation contains no hazardous substance in this category.

Other substances representing a hazard:
 No known substance in this category present.
Substances present at a concentration below the minimum danger threshold:
 Alumina : 25 <= x % < 50
 Titanium dioxide : 0 <= x % < 2.5
First Aid Measures

 As a general rule, in case of doubt or if symptoms persist, always call a
doctor.
 NEVER induce swallowing in an unconscious person.
 Move the affected person away from the contaminated area and into the fresh
air.
minutes) whilst keeping the eyes wide open.
 Consult an eye specialist if necessary.
 Rinse mouth out with water.
Fire-Fighting Measures
 Refractory material. Does not present any particular risk in the event of a fire.
 None to our knowledge. If there is a fire close by, use suitable extinguishing
agents.
Accidental Release Measures

 Since the product is in the form of balls, it can cause the floor to be very
slippery.
Handling and Storage

product is handled.
Handling:
42

Fire prevention:
Storage:
To guarantee the quality and properties of the product keep :
- protected from humidity and bad weather conditions.
Exposure Controls/Personal Protection

Technical measures:
 Personnel shall wear regularly laundered overalls.
If dust is generated:
 Anti-aerosol filters
 P3 (white)
Hand protection:
Type of gloves recommended: - PVC (polyvinylchloride)
 Safety spectacles with side shields.
Skin protection:
Physical and Chemical Properties

 Physical state : solid in granules
 Melting point/melting range : 2000 °C.
 Density : <1
 water solubility : Insoluble
Stability and Reactivity

 The preparation is stable at the handling and storage conditions recommended
per § 7 of the safety data sheet,
 Refractory product, stable at high temperatures.
Materials to avoid:
 Strong acids.
 Strong bases.
 The preparation contains no substance classed as hazardous per directive
67/548/EEC.
 Slightly irritating to the respiratory system.
 May cause slight temporary irritation.
 May cause irritation to eyes due to the presence of a foreign body.
Mobility:
43
 Slightly soluble product readily forms deposits.

Waste:
catalysts.
Soiled packaging:
 Give to a certified disposal contractor.
Regulatory Information
 This preparation was classified in compliance with the directive known as
<All preparations> 1999/45/EC and its adaptations
 In addition directive 2004/73/EC with the 29° adaptation of directive
67/548/EEC (Hazardous substances) have been taken into account.
 This preparation is not classed as hazardous to health by directive
1999/45/EC.
 This product is not classed as flammable.
Particular hazards associated with the preparation and safety
recommendations: Do not breathe dust.
More Information on ACT 069 Catalysts:

Product Name : ACT 069
Size : 19 mm
Volume : 2.945 m3
Estimated weight : 2592 kg
External diameter : 19mm
Average length : 9mm
Void fraction : 64%
Loading density : 0.88kg/l
Particle crushing strength : 220daN
ACT 069 has been developed to extend cycle length of units pressure drop due to
particulate deposition or top bed crust formation. ACT 069 replaces ineffective inert
balls used for bed hold-down at the top of catalytic reactors in liquid phase or
vapour phase service, such as refinery hydro treating and other similar applications.
44
The bed topping is a highly inert ceramic incorporating a special penta-ring shape
with a high void fraction to provide an efficient capture of particulates and other
contaminants in the feed. ACT 069 is one of the successive stages in Axens system
for pressure drop control.
The ceramic penta-rings provide a high void volume and a large void gap to trap
particulates and mitigate pressure drop build-up.
 Catalyst-ACT 077 specification & properties

Refinery catalyst for treating petroleum cuts.
1999/45/EC.
Other data:
Avoid the formation or spread of dust in the atmosphere.
This preparation contains no hazardous substance in this category.
Other substances representing a hazard:
 Titanium Dioxide
 Alumina : 50 <= x % < 100
First Aid Measures

doctor.
air.
45
minutes) by keeping the eyes wide open.
 Consult an eye specialist if necessary.
 If there is a fire close by, use suitable extinguishing agents.


product is handled.
Handling:
Fire prevention:
Storage:
To guarantee the quality and properties of the product keep :
- protected from humidity and bad weather conditions.

Technical measures:
 Personnel shall wear regularly laundered overalls.
If dust is generated:
Hand protection:

46
Density :<1
Water solubility : Insoluble.
Melting point/melting range : 2000 °C.

The preparation is stable at the handling and storage conditions recommended per §
7 of the safety data sheet,
Materials to avoid:
 Strong acids.
 Strong bases.
 The preparation contains no substance classed as hazardous per directive
67/548/EEC.
 Slightly irritating to the respiratory system.
 May cause slight temporary irritation.
 May cause irritation to eyes due to the presence of a foreign body.
Mobility:
Waste:
catalysts.
Soiled packaging:
67/548/EEC (Hazardous substances) has been taken into account.
47

1999/45/EC.

Size : 10 mm
Volume : 2.945 m3
External diameter : 10mm
Bore Diameter : 3.2mm
Pore Diameter : 2 µmm
Average length : 15mm
Void fraction : 65%
Loading density : 0.55kg/l
Particle crushing strength : 1 mini daN/mm
ACT 077 has been developed to extend cycle length of units pressure drop due to
particulate deposition or top bed crust formation. ACT 077 replaces ineffective inert
balls used for bed hold-down at the top of catalytic reactors in liquid phase or
vapour phase service, such as refinery hydro treating and other similar applications.
The bed topping is a highly inert alumina with a special fluted ring shape with a high
void fraction to provide an efficient capture of particulates and other contaminants in
the feed. ACT 077 is one of the successive stages in Axens system for pressure
drop control.
The alumina fluted rings provide a high void volume and a large void gap to trap
particulates and mitigate pressure drop build-up.

 Refinery catalyst for treating petroleum cuts.
48
 Alumina impregnated with molybdenum and nickel oxides.
Preparation classification: Toxic.
Other data:
Avoid the formation or spread of dust in the atmosphere.
NICKEL MONOXIDE : 2.5 <= x % < 10
MOLYBDENUM TRIOXIDE : 10 <= x % < 25
ALUMINA : 50 <= x % < 100
First Aid Measures

doctor.
ambulance.
air.

49
 None to our knowledge. If there is a fire close by, use suitable extinguishing
agents.

 Since the product is in the form of balls, it can cause the floor to be very
slippery.
regulations (see heading 13).
authorities in accordance with statutory procedures

product is handled.
products
Handling:
Fire prevention:

of the premises
50

preparation is used
Storage:

products.
Technical measures:
 If this ventilation is insufficient to maintain the concentration of vapors below
the exposure limits, wear breathing apparatus
 Biff dust is generated:
Hand protection:
Skin protection:

Density :<1
water solubility : Insoluble.
melting point/melting range : 2000 °C.

Materials to avoid:
 No data is available regarding the preparation itself.
 The product must not be allowed to run into drains or waterways.
51
Mobility:
Waste:
catalysts.
Soiled packaging:
Contains: Nickel Monoxide & Molybdenum Trioxide

recommendations:
 Wear suitable gloves.
 In case of accident or if you feel unwell, seek medical advice immediately
(show the label where possible).
 Do not breathe dust.
 Wear suitable protective clothing.
 In case of insufficient ventilation, wear suitable respiratory equipment.
 This material and its container must be disposed of as hazardous waste.
 Product not to be sold to the general public.
Particular provisions:
 Product not to be sold to the general public. (Dir 76/769/EC) - For
professional use only.
52
Attention - Avoid exposure - obtain special instructions before use.

Size : 5 mm
Volume : 10.014 m3
External diameter : 4 to 6.3mm
Nickel (NiO) : 2.5wt%
Molybdenum (MoO3) : 12wt%
Loss of ignition @ 550°C : 4 max wt%
Surface Area : 115m2/g
Total pore volume : 0.9cm3/g
Sock loading density : 0.48Kg/l
Dense loading density : 0.50Kg/l
ACT 645 is used as top bed grading material upstream the main catalytic bed in the
hydro treatment of hydrocarbon cuts including naphtha, gasoil or vacuum gasoil.
ACT 645 acts as an hydro treatment catalyst and its main purpose is to remove
organic iron and organo metallic complexes that could be present in the feed. Its
selected carrier, highly porous alumina, provides a very efficient trapping of metals,
carbon particles and pollutants of the feed.
ACT 645 can be used in combination with CoMo or NiMo catalysts. The bead shape
makes it easy to handle. Its size allows creating a gradient of particle size at the top
of the reactor. The attrition resistance is particularly high.
ACT 645 is available under oxide form and has to be sulfided to be active.
53

 Refinery catalyst for treating petroleum cuts.
 Alumina impregnated with molybdenum and nickel oxides.
Full text of risk phrases appearing in section 3: see section 16.
Nickel Monoxide : 2.5 <= x % < 10
Molybdenum Trioxide : 10 <= x % < 25
Alumina : 50 <= x % < 100
54
First Aid Measures

doctor.
ambulance.
air.
 If there is a fire close by, use suitable extinguishing agents.

regulations (see heading 13).
authorities in accordance with statutory procedures

product is handled.
products
Handling:
Fire prevention:
55

of the premises
preparation is used
Storage:

products.
Technical measures:
 If this ventilation is insufficient to maintain the concentration of vapors below
the exposure limits, wear breathing apparatus
 If dust is generated:
Hand protection:
Skin protection:

Density : <1
Water solubility : Insoluble.
Melting point/melting range : 2000 °C.

Materials to avoid:
56
The product must not be allowed to run into drains or waterways.
Mobility:
Slightly soluble product readily forms deposits.
Inert mineral product. Not degradable.
Preparation classification:
Contains: Nickel Monoxide & Molybdenum Trioxide
recommendations:
 Wear suitable gloves.
 In case of accident or if you feel unwell, seek medical advice immediately
(show the label where possible).
 Do not breathe dust.
 Wear suitable protective clothing.
 In case of insufficient ventilation, wear suitable respiratory equipment.
 This material and its container must be disposed of as hazardous waste.
 Product not to be sold to the general public.
Particular provisions:
 Product not to be sold to the general public. (Dir 76/769/EC) - For
professional use only.
 Attention - Avoid exposure - obtain special instructions before use.

(Nickel and molybdenum oxides on special alumina, cylindrical extrudates)
57

Size : 2.5 mm
Loading Type : Sock
Volume : 49.087 m3
External diameter : 1.6 to 2.5mm
Nickel (NiO) : 3.8 wt%
Molybdenum (MoO3) : 9.0 wt%
Loss of ignition @ 550°C : 2 max wt%
Surface Area : 350m2/g
Total pore volume : 65 Cm3/g
Sock loading density : 520Kg/m3
Dense loading density : 600Kg/m3
Particle crushing Strength : 0.9 daN/mm
ACT 961, Silica trap material

For silicon removal, Axens has recently developed a catalyst for this specific
application. The surface area and the texture of support have been optimised. When
processing Coker naphtha, the end of cycle is most often linked to the limited silicon
adsorption capacity of the catalyst. Indeed, when silicon is not present, typical cycle
lengths for naphtha hydro treating catalysts are above 3 to 4 years. But, when
processing Coker naphtha, the cycle length of the catalyst is less than 1 year and
even less. The silicon breakthrough will irreversibly damage the downstream
catalysts (reforming, isomerisation).
Our new silicon trap catalyst is a NiMo type. Consequently it is very active for
hydrolysis of organic silicon but it also promotes the saturation of the remaining
diolefins and olefins and the nitrogen removal.
Thanks to its optimised texture and porosity, the ACT961 catalyst has a very high
Silicon retention.
 Inert ceramic ball-1/4” & 3/4” specification & properties
Ceramic/Alumina Balls 1/4”

Nom. Size : 1/4”
Range Diameter (MM) : 5-8
Surface Area : 520
Bulk Density (Kg/M3) : 1400
58
Crushing Load min. (Kg) : 80
Ceramic/Alumina Balls 3/4”

Nom. Size : 3/4”
Range Diameter (MM) : 17-21
Surface Area : 190
Bulk Density (Kg/M3) : 1380
Crushing Load min. (Kg) : 430
Chemical Composition:
AI2O3 + SiO2 : 95% min.
SiO2 : 65-75%
Al2O3 : 23-28%
Fe2O3 + TiO2 : 1.2% Max.
MgO + CaO : 1.5% Max.
Na2O + K2O : 3.5% Max
Fe (Leachable) : <0.1%
Physical Properties:
Free of Space : 40%
Attrition : <0.05%
Mol. Surface Area : <0.08m2/gr.
Particle Density : 2.4 g/cc
Water Absorption : 0.1-2.0 wt%
Hardness (Mohs Scale) : 6-7
Max. Application Temp. : 1000°C
Sphericity : 1.2
Identification of the Substance: Ceramic Balls

Composition of Ingredients: Clay based sintered spheres & other shapes.
Emergency First aid: Material totally Inert, No health hazard.
Fire Fighting Measures:
Inflamability : None
Extinguishing Media : Not inflammable.
Decomposition Temp. : Does not decompose.
Special Fire fighting Instruction : None
Accidental Release Measures: The precautionary measures usually employed in

handling minerals should be observed.
Handling & Storage: No special care needed.

Physical Data:
Odour : None
Form : Lumps
Colour : Light Brown
Solubility in H2O : Nil

Instability : None
Polymerisation : Does not occur
59
Oxidiser Props : None

Dangerous Decomposition Product : None
Toxicological Information: NA
Ecological Information:
Mobility : NA
Persistence/Degradability : NA
Bloaccumulation : NA
Disposal Consiseration: Can be disposed in special waste disposal units with local
regulations.
 MSDS of Dimethyl Disulphide
Product Identification & Use

Product Identifier : Dimethyl Disulphide
Product Code : ORG0719
Product Use : Sulphiding Agent
Whims Classification : B2 – Flammable Liquid
.
Hazardous Ingredients:
Dimethyl Disulphide:
%W/W : 99
CAS # : 624-92-0
TLV : ACGIH TWA = 0.5PPM (SKIN)
Physical Data:
Physical State : Liquid
Odour & Appearance : Pale yellow liquid, strong garlic like odour
60
Odour Threshold : 8-10 (ppb)

Specific Gravity/Density : 1.063 @ 20°C
Vapour Pressure : 0.42 PSIA
Vapour Density (Air=1) : 3.25
Volatility/Vol. (%) : 100
Solubility in Water : Insoluble
Evaporation Rate : NE
Boiling Point : 107-110 °C (225-232 °F)
Freezing Point : -84.7°C (-120.5°F)
PH : NA
Fire & Explosion Hazard:

Flammability : Flammable.
Conditions : Heat, Sparks, Open flames.
Means of Extinction : Water Spray, Carbon Dioxide, Foam or Dry
Chemical. Water may be ineffective.
Flash Point : 16°C (TCC)
Upper Explosion Limit (% V) : 16
Lower Explosion Limit (%V) : 1.1
Auto-Ignition Temperature : 300°C (572°F)
Hazardous Combustion Products : Oxides of Carbon, Sulphur Oxides, H2S.
Explosion Data : NE
Sensitivity to Impact : NO
Sensitivity to Static Discharge : NO
Reactivity:
Chemical Stability : Stable
Incompatible materials : Solid bleach, Strong oxidizers, Reducing
agents, Corrosive to Copper and Copper
Alloys.
Conditions of reactivity : Decomposition temperature: 390°c.
Hazardous decomposition Products : Hydrogen Sulphide, Methyl Mercaptans.
Health Hazard & Information:

Route of Entry
Skin Contact : May cause irritation
Skin Absorption : NE
Eye : May cause irritation.
Ingestion : Harmful if swallowed.
Inhalation : Harmful if inhaled.
Acute over exposure effects : NE
Chronic over exposure effects : NE
Sensitization : Does not meet Whmis criteria.
Carcinogenicity : Does not meet Whmis criteria.
Teratogenicity : Does not meet whmis criteria.
Mutagenicity : Does not meet whmis criteria.
Reproductive toxicity : Does not meet whmis criteria.
Preventive Measures
61
Personal protective equipment : Wear safety goggles and impervious

gloves. where airborne exposure is likely,
wear a NIOSH approved respirator equipped
with an organic vapour cartridge.
Specific Engineering Controls : Local exhaust is recommended.
Leak and Spill procedures : Absorb small spills with sand. Dike large
spills and cover with foam or water spray to
reduce vapour emissions. Transfer to a
closed container. Treat area with household
bleach to eliminate odour. Do not use solid
bleach.
Waste Disposal : Hazardous waste. Do not allow product to
enter the environment.
Handling procedures : keep away from heat, sparks and open
flames. wash before eating, drinking, using
tobacco products or rest rooms.
Storage requirements : keep in a closed, labelled container in a
ventilated area. Containers are hazardous
when it is empty.
First aid measures

Eye : Flush eyes with large amount of water for 15 minutes while holding
eyelids open. Seek medical attention.
Skin : Wash skin with water and soap. Seek medical attention if irritation
occurs or persists.
Ingestion : Do not give liquids if person is unconscious or very drowsy. Do not
induce vomiting. Seek immediate medical attention.
Inhalation : Remove person to fresh air immediately. If breathing has stopped,
apply artificial respiration and administer Oxygen if necessary. Seek
medical attention.
62
 MSDS of Methyldiethanolamine:
Product Identification
Product Name : Methyldiethanolamine
Product Synonym(s) : MDEA
Chemical Family : Alkyl Alkanolamine
Chemical Formula : CH3N(C2H4OH)2
Chemical Name : Ethanol, 2,2’-(Methylimino) bis-
Composition/Information on Ingredients:
Ingredient Name CAS Registry Number Typical Wt. % OSHA

Methyldiethanolamine 105-59-9 99% Y
Water 7732-18-5 0.3% N
The substance(s) marked with a "Y" in the OSHA column, are identified as hazardous
chemicals according to the criteria of the OSHA Hazard Communication Standard (29
CFR 1910.1200). The components of this product are all on the TSCA Inventory list.
Emergency Overview
Potential Health Effects
Pale straw liquid with amine odour
WARNING!
CAUSES EYE IRRITATION.
Inhalation and skin contact are expected to be the primary routes of occupational
exposure to this material. Based on single exposure animal tests, it is considered to
be slightly toxic if swallowed, practically non-toxic if absorbed through skin,
severely irritating to eyes and practically non-irritating to skin.
IF IN EYES, immediately flush with plenty of water for at least 15 minutes. Get
medical attention.
IF ON SKIN, immediately flush with plenty of water. Remove contaminated clothing
and shoes. Get medical
Attention. Wash clothing before reuse. Thoroughly clean shoes before reuse.
63
If swallowed, do NOT induce vomiting. Give water to drink. Get medical attention
immediately. NEVER
IF INHALED, remove to fresh air. If not breathing, give artificial respiration. If

breathing is difficult, give oxygen. Get medical attention.
Fire Fighting Measures

Fire and Explosive Properties
Auto-Ignition Temperature : 770 F (410 C)

Flash Point : 240 F Flash Point Method PMCC
Flammable Limits
Upper : 8.8
Lower : 1.4
Extinguishing Media: Use water spray, carbon dioxide, foam or dry chemical.
Fire Fighting Instructions

Fire and Explosion Hazards
Use water spray, carbon dioxide, foam or dry chemical. Fire fighters and others who
may be exposed to products of combustion should wear full fire fighting turn out
gear (full Bunker Gear) and self-contained breathing apparatus (pressure demand
NIOSH approved or equivalent). Fire fighting equipment should be thoroughly
decontaminated after use. When burned, the following hazardous products of
combustion can occur Oxides of carbon and nitrogen.

Handling
Small spills may be flushed away with large volume of water. Consult a regulatory
specialist to determine appropriate state or local reporting requirements, for
assistance in waste characterization and/or hazardous waste disposal and other
requirements listed in pertinent environmental permits.
Handling & Storage:

1) Avoid contact with eyes.
2) Wash thoroughly after handling.
3) Emptied container retains vapour and product residue. Observe all labelled
safeguards until container is cleaned, reconditioned or destroyed.
Storage
This material is not hazardous under normal storage conditions; however, material
should be stored in closed containers, in a secure area to prevent container damage
and subsequent spillage.

Engineering Controls
64
Investigate engineering techniques to reduce exposures. Provide ventilation if

necessary to minimize exposure. Dilution ventilation is acceptable, but local
mechanical exhaust ventilation preferred, if practical, at sources of air contamination
such as open process equipment.
Eye / Face Protection:

Where there is potential for eye contact, wear chemical goggles and have eye
flushing equipment immediately available.
Skin Protection:
Minimize skin contamination by following good industrial hygiene practice. Wearing
rubber gloves is recommended. Wash hands and contaminated skin thoroughly after
handling.
Respiratory Protection:
Where airborne exposure is likely, use NIOSH approved respiratory protection
equipment appropriate to the material and/or its components. If exposures cannot be
kept at a minimum with engineering controls, consult respirator manufacturer to
determine appropriate type equipment for a given application. Observe respirator
use limitations specified by NIOSH or the manufacturer. For emergency and other
conditions where there may be a potential for significant exposure, use an approved
full face positive-pressure, self-contained breathing apparatus or positive-pressure
airline with auxiliary self-contained air supply. Respiratory protection programs
must comply with 29 CFR § 1910.134.
Physical & Chemical Properties:

Appearance/Odour: Pale straw liquid with amine odour
pH: NE
Specific Gravity : 1.05 @ 20 C
Vapour Pressure : <0.01 mmHg @ 20 C
Vapour Density : 4
Melting Point : NA
Freezing Point : -21 C (-5.8 F)
Boiling Point : 240-255 C (464-491 F )
Solubility In Water : Complete
Evaporation Rate : NE
Percent Volatile : 100
Molecular Weight : 119.2

Stability: This material is chemically stable under normal and anticipated storage
and handling conditions.
Incompatibility: Avoid contact with strong acids, strong alkalis, and strong
oxidizers.
Hazardous Decomposition Products: Thermal decomposition giving off toxic and
corrosive products: ammonia, carbon dioxide, nitrogen dioxides.
Data on this material and/or its components are summarized below.
Single exposure (acute) studies indicate:
Oral : Slightly Toxic to Rats (LD50 4,780 mg/kg)
Dermal : Practically Non-toxic to Rabbits (LD50 6,300 mg/kg)
65
Inhalation : No deaths in rats following exposure to saturated vapour for 8-hours

Eye Irritation : Severely Irritating to Rabbits (59/110)
Skin Irritation: Practically Non-irritating to Rabbits (4-hr exposure, 0.2/8.0)
No skin allergy was observed in guinea pigs following repeated exposure. Severe
irritations, but no systemic effects, were observed following repeated application to
the skin of rats. No birth defects were observed in the offspring of rats following
application to the skin during pregnancy, even a doses which produced adverse
effects on the mothers. No genetic changes were observed in tests using bacteria or
animals.
Disposal Considerations:
Incineration is the recommended method for disposal observing all local, state and
federal regulations. Note: Chemical additions to, processing of, or otherwise altering
this material may make this waste management information incomplete, inaccurate,
or otherwise inappropriate. Furthermore, state and local waste disposal
requirements may be more restrictive or otherwise different from federal laws and
regulations.
 MSDS of Sodium carbonate

Chemical Product and Company Identification:
Product Name : Sodium carbonate
Catalogue Codes : SLS3481, SLS1264, SLS4105, SLS1894,SLS3316
CAS# : 497-19-8
66
Synonym : Crystal Carbonate, Disodium Carbonate, Sal Soda, Soda

Ash, Washing Soda
Chemical Name : Sodium Carbonate, Anhydrous,
Chemical Formula : Na2-C-O3
Hazards Identification:
Potential Acute Health Effects: Hazardous in case of skin contact (irritant), of eye
contact (irritant), of ingestion, of inhalation (lung irritant).
Potential Chronic Health Effects:
Slightly hazardous in case of skin contact (sensitizer).
Carcinogenic Effects : Not available.
Mutagenic Effects : Not available.
Teratogenic Effects : Not available.
Delopmental Toxicity : Not available. The substance may be toxic to
upper respiratory tract, skin, and eyes. Repeated or prolonged exposure to the
substance can produce target organs damage.
First Aid Measures:

Eye Contact: Check for and remove any contact lenses. In case of contact,
immediately flush eyes with plenty of water for at least 15 minutes. Cold water may
be used. Get medical attention.
Skin Contact: In case of contact, immediately flush skin with plenty of water. Cover
the irritated skin with an emollient. Remove contaminated clothing and shoes. Cold
water may be used. Wash clothing before reuse. Thoroughly clean shoes before
reuse. Get medical attention.
Serious Skin Contact: Wash with a disinfectant soap and cover the contaminated
skin with an anti-bacterial cream. Seek immediate medical attention.
Inhalation: If inhaled, remove to fresh air. If not breathing, give artificial respiration.
If breathing is difficult, give oxygen. Get medical attention.
Serious Inhalation: Not available.
Ingestion: Do NOT induce vomiting unless directed to do so by medical personnel.

Never give anything by mouth to an unconscious person. Loosen tight clothing such
as a collar, tie, belt or waistband. Get medical attention if symptoms appear.
Serious Ingestion: Not available.
Fire and Explosion Data:

Flammability of the Product : Non-flammable.
Auto-Ignition Temperature : Not applicable.
Flash Points : Not applicable.
Flammable Limits : Not applicable.
Products of Combustion : Emits Na2O fumes when heated to
decomposition.
Fire Hazards in Presence of Various Substances : Not applicable.
67
Explosion Hazards in Presence of Various Substances: Risks of explosion of the

product in presence of mechanical impact: Not available. Risks of explosion of the
product in presence of static discharge: Not available.
Fire Fighting Media and Instructions : Not applicable.
Special Remarks on Fire Hazards:

Sodium carbonate can ignite and burn fiercely in contact with fluoride. Sodium
Carbonate in contact with fluorine decomposed at ordinary temperature with
incandescence.
Special Remarks on Explosion Hazards: Reacts explosively with red-hot

aluminium metal. Sodium carbonate + ammonia in arabic gum solution will explode.

Small Spill:
Use appropriate tools to put the spilled solid in a convenient waste disposal
container. If necessary: Neutralize the residue with a dilute solution of acetic acid.
Finish cleaning by spreading water on the contaminated surface and dispose of
according to local and regional authority requirements.
Large Spill: Use a shovel to put the material into a convenient waste disposal
container. Neutralize the residue with a dilute solution of acetic acid. Finish cleaning
by spreading water on the contaminated surface and allow to evacuate through the
sanitary system.
Handling and Storage:

Precautions: Do not ingest. Do not breathe dust. Wear suitable protective clothing.
In case of insufficient ventilation, wear suitable respiratory equipment. If ingested,
seek medical advice immediately and show the container or the label. Avoid contact
with skin and eyes. Keep away from incompatibles such as acids.
Storage: Hygroscopic. Keep container tightly closed. Keep container in a cool, well-
ventilated area. Do not store above 24°C (75.2°F). Hygroscopic.

Engineering Controls: Use process enclosures, local exhaust ventilation, or other
engineering controls to keep airborne levels below recommended exposure limits. If
user operations generate dust, fume or mist, use ventilation to keep exposure to
airborne contaminants below the exposure limit.
Personal Protection: Splash goggles. Lab coat. Dust respirator. Be sure to use an
approved/certified respirator or equivalent. Gloves.
Personal Protection in Case of a Large Spill: Splash goggles. Full Suit, Dust
respirator. Boots. Gloves. A self contained breathing apparatus should be used to
avoid inhalation of the product. Suggested protective clothing might not be sufficient;
consult a specialist BEFORE handling this product.
Exposure Limits: Not available.
Physical and Chemical Properties:

Physical state and appearance : Solid. (Powder)
Odour : Odourless.
68
Taste : Alkaline.
Molecular Weight : 105.99 g/mole
Colour : White.
pH (1% soln/water) : 11.5 [Basic.]
Boiling Point : Not available.
Melting Point : 851°C (1563.8°F)
Critical Temperature : Not available.
Specific Gravity: Density : 2.532 (Water = 1)
Dispersion Properties : See solubility in water.
Solubility : Soluble in hot water, glycerol. Partially
soluble in cold water. Insoluble in acetone &
alcohol.
Stability : The product is stable.
Instability Temperature : Not available.
Conditions of Instability : Incompatible materials, moisture
Incompatibility with various substances: Reactive with acids. Slightly reactive to
moisture.
Corrosivity: Non-corrosive in presence of glass.
Special Remarks on Reactivity: Hygroscopic. Combines with water & evolve heat.
Incompatible with phosphorus pentoxide, lithium, fluorine, fluoride, ammonia + silver
nitrate, 2,4,6-trinitrotoluene, ammonia, acids, sodium sulphide + water, hydrogen
peroxide, red hot alumium metal, sodium sulphide, zinc, calcium hydroxide. Sodium
Carbonate is decomposed by acids with effervescence. Reacts violently with F2,
Lithium, and 2,4,6-trinitrotoluene. Sodium begins to decompose at 400 C to evolve
CO2.
Special Remarks on Corrosivity: Hot concentrated solutions of sodium carbonate
are mildly corrosive to steel.
Polymerization: Will not occur.
Toxicological Information:
Routes of Entry: Inhalation. Ingestion.
Chronic Effects on Humans: May cause damage to the following organs: upper
respiratory tract, skin, eyes.
Other Toxic Effects on Humans: Hazardous in case of skin contact (irritant), of
ingestion, of inhalation (lung irritant).
Special Remarks on Toxicity to Animals: LDL (Lowest Published Lethal Dose)
[Man] - Route: Oral; Dose: 714 mg/kg
Special Remarks on Chronic Effects on Humans: May cause adverse
reproductive effects based on animal test data
Special Remarks on other Toxic Effects on Humans:
Acute Potential Health Effects: Skin: Causes skin irritation with possible burns
depending on the concentration, site (abraded or intact skin), and duration of
exposure. Eyes: Causes eye irritation and possible burns. Concentrated solutions
may cause permanent corneal injury (permanent corneal opacity). Ingestion: Sodium
carbonate ingestion may cause irritation of the digestive tract resulting in nausea,
vomiting, diarrhea, thirst, abdominal pain depending on concentration and amount
ingested. May also affect the cardiovascular system. Inhalation: Dust may cause
respiratory tract and mucous membrane irritation with coughing and shortness of
breath (dyspnea), pulmonary edema. Chronic Potential Health Effects: Chronic
inhalation may result in decreased pulmonary function, nasal congestion, nosebleeds,
69
perforation of the nasal septum. Other effects of chronic exposure are skin
(dermatitis and ulceration), and gastrointestinal complaints. However, the effects of
chronic exposure seem to be reversible if exposure is decreased.
Disposal Considerations: Waste must be disposed of in accordance with federal,

state and local environmental control regulations.
 MSDS of Sodium Hydroxide:

Identification:
Product Name : Sodium Hydroxide
Other Names : Not available
Product Code : C200, C2005
U.N. Number : UN1823
Dangerous Goods Class : 8
and Subsidiary Risk : None allocated
Hazchem Code : 2X
Poison Schedule : S6
Use : Common caustic solution
Physical Description and Properties
Appearance : White, deliquescent, odourless pellets
Boiling Point/Melting Point : BP 1388oC; MP 318oC
Vapour Pressure :0
Specific Gravity : 2.1
Flash Point : Not applicable
Flammability Limits : Not determined
Solubility in water : 1111g/L, approx.54% @ 200C
Health Effects:
Acute: Will cause severe irritation and chemical burns to the gastrointestinal tract.
Swallowed: Symptoms include severe abdominal pain, vomiting and diarrhoea.
Eye: Corrosive. Can cause permanent eye damage and blindness. Severe pain and
tearing.
Skin: Will cause severe irritation and chemical burns in contact with the skin, which
can result in tissue destruction.
70
Inhaled: Dusts and mists will cause severe irritation and chemical burns to the
respiratory tract.
First Aid:
Swallowed: Do not induce vomiting. Immediately wash out mouth with water and
then give plenty of water to drink. Seek immediate medical attention.
Eye: Immediately flush eyes with plenty of water for approximately 20 minutes
holding eyelid open. Call a doctor immediately.
Skin: Remove all contaminated clothing. Wash gently and thoroughly with water for
15 minutes. Ensure contaminated clothing is washed before re-use or discard. If
contact is more than of minor nature, seek medical attention.
Inhaled: Remove the source of contamination or move the victim to fresh air. Ensure
airways are clear and have qualified person give oxygen through a face mask if
breathing is difficult. If victim has stopped breathing begin artificial respiration, or if
heart has stopped, cardiopulmonary resuscitation.
First Aid Facilities: Safety showers, eye wash and normal washroom facilities.
Advice to Doctor: Corrosive. May cause stricture. If lavage is performed,
endotraceal and/or esophagoscopic control is suggested. Material is strong alkali. If
skin burns are present, treat as any thermal burn after decontamination. Eye
irrigation may be necessary for extended period of time to remove as much alkali as
possible.
Duration of irrigation and treatment is at the discretion of attending medical
personnel. No specific antidote. Supportive care suggested. Treatment based on
judgement of attending physician and reaction of patient.
Precautions for use
Exposure Standards: TWA 2mg/m3. Permissible exposure limit (PEL) 2mg/m3
Engineering Controls: Where dust is generated the use of a mechanical exhaust
ventilation system is recommended.
Personal Protection: Protection of hands: the use of Nitrile or Neoprene gloves is
recommended. Eye protection: The use of face shields, chemical goggles or safety
glasses with side shield protection complying with AS/NZS 1337 is recommended.
Body protection: The use of plastic apron, sleeves overalls and rubber boots is
recommended.
Where ventilation is inadequate the use of a Class P1 or P2 respirator complying
with AS/NZS 1715 and 1716 is recommended.
Flammability: Not flammable under conditions of use.
Safe Handling Information:
Storage and Transport: Requirements to be met by storerooms and containers:
Provide alkali-resistant floor. Unsuitable material for container: aluminium, zinc, tin,
lead, glass. Do not store together with acids, oxidisers and chlorinated organic
compounds. This product is hydroscopic. Protect from humidity and keep away from
water.
Protect for carbon dioxide. Store upright in cool, dry well ventilated area in well
sealed containers. Remove closure carefully to release possible internal pressure.
Spills and Disposal:
1) Wear protective equipment. Keep unprotected persons away.
2) Do not allow to enter drainage system, surface or ground water.
3) Do not allow to enter the ground/soil. Sweep or vacuum material avoiding dust
generation.
4) Ensure adequate ventilation.
71
5) Dispose of contaminated material as waste. Must not be disposed of together

with household garbage.
6) Do not allow product to reach sewage system.
7) Dispose in accordance with local, state and federal EPA waste regulations.
8) Neutralisation is the preferred method of disposal.
Fire/Explosion Hazard: Solutions may react with aluminium and other soft metals
to generate hydrogen which is flammable and/or explosive if ignited. Suitable
extinguishing agents: Carbon dioxide; fire-extinguishing powder; dry
sand; cement. Wear self-contained breathing apparatus. Wear full protective suit.
Hazardous Reaction Heat generated upon dilution with water. Dilute only by adding
to water with agitation. Do not add water to sodium hydroxide.
 MSDS of Ammonia
Identification:
1) Product Name: Ammonia
2) Chemical formula :NH3
1) Liquefied Gas
2) Toxic by Inhalation
3) Corrosive to Eyes
First aid Measures:
Inhalation: Toxic by inhalation. Remove victim to uncontaminated area wearing self
contained breathing apparatus. Keep victim warm & rested. Apply artificial
respiration if breathing is stopped.
Skin or Eye contact: May cause chemical burns to skin & cornea (with temporary
disturbance to vision). Immediately flush the eyes thoroughly flush eyes with water
for at least 15 minutes. Remove contaminated clothing. Drench affected area with
water for at least 15 minutes. Obtain medical assistance.
Ingestion: Ingestion is not considered a potential route of exposure.
Fire Fighting measures:

Specific Hazards: Non Flammable. Exposure to fire may cause containers to rupture
or explode. Hazardous combustion products: If involved in a fire the following toxic
and or corrosive fumes may be produced by thermal decomposition.
 Nitric Oxide
 Nitrogen Dioxide.
Suitable Extinguishing Media: All known extinguishers can be used.
Specific methods: If possible stop flow of products. Move away from the container &
cool with water from protected position.
Special protective equipment for Fire fighting: Use self contained breathing
apparatus & chemically protective clothing.
Accidental release measures:

Personnel precautions:
 Evacuate Area.
 Ensure adequate air ventilation.
 Use self contained breathing apparatus & chemically protective clothing.
Environmental aspects:
72
 Try to stop leakage/release.

 Reduce vapour with fog or fine water spray
Clean up methods:
 Wash contaminated equipment or sites of leaks with copious quantity of
water.
 Keep area evacuated and free from ignition sources until any spilled liquid has
evaporated (ground free from frost)
 Hose down area with water.
Handling & storage:

 Keep container below 50°C in a well ventilated place.
 Refers to supplier’s container handling instructions.
 Use only properly specified equipment which is suitable for this product, its
supply pressure & temperature. Contact your gas supplier if in doubt.
 Do not allow back feed in to the container.
 Suck back of water into the container must be prevented.
 Segregate from oxidant gases and other oxidants in store.
 Keep away from ignition sources (including static charges).
 Purge air from system before introducing gas.
Exposure limit (TLV): 25PPM
Personnel Protection:
 Keep suitable chemically resistant protective clothing readily available for
emergency use.
 Keep self contained breathing apparatus available for emergency use.
 Don’t smoke while handling products.
 Ensure adequate ventilation.
 Protect eyes, face & skin from liquid splashes

Molecular Weight : 17
Melting Point : -77.7°C
Boiling Point : -33°C
Critical Temperature : 132°C
Relative Density, gas : 0.6 (air=1)
Relative Density, Liquid : 0.7 (air=1)
Vapour pressure @20°C : 8.6Bar
Solubility mg/l water : Hydrolysis
Appearance/colour : Colour less gas
Odour : Ammonical
Auto ignition temperature : 630°C
Flammability range : 15-30 vol% in air
Other Data: Although this substance has flammability data, it is difficult to ignite in
air & classified as non- flammable

 May react violently with oxidants.
73
 May react violently with acids.

 Reacts with water to form corrosive alkalis.
 Can form explosive mixture with air
Toxicological Information: May cause inflammation of the respiratory system and

skin. Inhalation of large amounts leads bronchospasm, laryngeal oedema & pseudo
membrane formation.
Ecological Information: May cause pH changes in aqueous ecological systems.
 Avoid discharge to atmosphere.
 Don’t discharge into any place where its accumulation could be dangerous.
 Don’t discharge into areas where there is a risk of forming an explosive
mixture with air.
 Gas may be scrubbed in Sulphuric acid solution.
 Gas may be scrubbed in water.
 Toxic and corrosive gases formed during combustion should be scrubbed
before discharge to atmosphere.
 Contact supplier if guidance is required.
 Anti Foam Agent (SR 1729 – Dorf Ketal:
74
Description: SR 1729 is an Organic liquid antifoam used to control foaming and

carryover in amine units and steam generators in refinery & Petrochemical
complexes
Features:
 Optimises concentration cycles.
 Effective foam control
 Easy to dose.
Applications: SR 1729 silicone free anti foam allow maximizing the cycles of
concentration at proper treatment levels. Its quick action will reduce tower pressure
instantaneously.
Dosage: Specific dosage and feed rates vary depending upon the application.
Dosage varies from 1 to 10 ppm.
Typical Properties:
Appearance : Clear colour less to amber coloured liquid.
Sp.Gr. @15.6°C : Max.250cSt
K.V.@ 40°C : Max. 250cSt
Benefits
 Lowers Tower/Equipment pressure
 Energy & treatment cost savings.
 Maximises equipment life & steam use.
 Reduces handling time & labour costs
 Improved heat transfer and operating control.
 No silicone, metals or halogens
Packaging: SR 1729 is available in 180kgs net MS drums.
Identification of the substances:

Trade Name : SR 1729
Type of Use : Antifoam
Identification of the Company : Dorf Ketal chemicals India Pvt. Ltd.
Composition/Information of the Ingredients: Co-Polymer of Easters
Hazardous Identification; Primary route of Exposure:

Skin contact: Causes mild moderate irritation on brief skin contact. Prolonged
contact with skin will cause moderate to severe irritation or possibly burns where
clothing is confined. Repeated or prolonged contact may result in dermatitis due to
defatting solvent properties.
Eye Contact: Contact with eyes will result in severe irritation or burns and in
extreme cases may result in permanent injury if not promptly removed from eyes.
Ingestion: May cause severe gastrointestinal distress with nausea, vomiting and
diarrhea. Aspiration in to lungs may cause pulmonary oedema and chemical
pneumonitis. Ready absorbed through the gastrointestinal tract.
Inhalation: Exposure may result in eye, nose and respiratory irritation and may
produce nausea, headache, and dizziness. Prolonged exposure to elevated
concentrations makes cause weakness and CNS depression. In extreme cases,
drowsiness and even loss of consciousness may occur.
75
First aid measures:

Eye Contact: If in eyes, irrigate with flowing water immediately and continuously for
fifteen minutes. Get medical attention promptly.
After Inhalation: If inhaled, remove to fresh air. Administer oxygen if necessary. Get
medical attention if symptoms persist or exposure was severe.
Skin Contact: Wash skin thoroughly with soap & Water. If rash or irritation develops,
get medical attention. Launder clothing before re use.
After ingestion: Due to possible aspiration in to Lungs, DO NOT induce vomiting if
Ingested. Get medical attention immediately.
Fire fighting Measures:

Suitable Extinguisher media: None
Fire and Explosion Hazards: Use water to keep fire exposed containers cool. If leak
or spill has not ignited, use water spray to disperse the vapours and protect men
attempting to stop leakage. Fire fighters must use breathing apparatus in the
enclosed area.
Special protective equipment: Fire fighters and others exposed should wear a self
contained breathing apparatus.

Personnel protection: Avoid breathing of vapours and contact with eyes, skin or
clothing. Keep container closed when not in use.
Small spill: Absorb on paper, cloth or other material.
Large Spill: Dyke to prevent any sewer or water way. Transfer liquid to a holding
container. Cover residue with dirt, or suitable chemical absorbent. Use personnel
protective equipment as necessary.
Handling & Storage:

Handling: When handling the material, good hygiene practices should be observed.
Avoid prolonged and repeated exposure.
Storage: The drums should be stored, with their seals intact, in conditions that avoid
extremes of temperatures. Bulk deliveries should be stored in carbon steel tanks.
Under these conditions the shelf life of the product would approx. 2 years.
Exposure controls/Personal protection:

Respiratory Protection: When Concentration exceeds the exposure limits specified,
use of an approved organic vapour cartridge respirator is recommended. Where the
protection factor of the respirator may be exceeded, use of a self contained
breathing unit may be necessary.
Ventilation: General ventilation should be provided to maintain ambient
concentrations below nuisance levels. Local ventilation of emission sources may be
necessary to maintain ambient concentrations below recommended exposure limits.
Protective clothing: Chemical resistant gloves and chemical goggles should be used
to prevent skin & Eye contact.

Form : Liquid
Colour : Lear colour less to amber
Odour : NA
76
Relative density / Sp. Gr. : 0.97-1.10 @ 15.6°C

Kinematic viscosity : Max.250cSt @ 40°C
Stability:
Stability: Stable under normal conditions of storage and use.
Incompatibility: Keep away from strong oxidising agents, heat and open flames.
Hazardous Polymerisation: will not occur.
Disposal consideration:
Provisions relating to waste: Hazardous product residue may remain in emptied
container.
Disposal information: Place chemical residue and contaminated absorbent materials
in to suitable waste container and take to an approved waste disposal site. Dispose
of all residues in accordance with applicable waste management regulations.
 Lubricity agent (SR 2036-Dorf Ketal):

Property:
Appearance: Clear yellow to amber liquid
Specific gravity @ 15.6°C : 0.88-0.93
Kinematic viscosity at 40°C : 7-22
Flash point : ≥ 62
Pour point : ≤0

Type of Use : Lubricity additive
Emergency overview: Product is a yellow liquid with a slight fatty acid odour.
Product is not considered to be combustible. However, after prolonged contact with
highly porous materials, this product may spontaneously combust. May cause eye &
skin irritation. If heated product contacts the eye and/or skin, thermal burns may
result. Inhalation of mists/vapours/fumes generated by heating this product may
77
cause respiratory irritation with throat discomfort, coughing or difficulty breathing.

Aspiration in to lungs may cause chemical pneumonitis and pulmonary edema.
Potential health effects:
Eye Contact: Product may cause eye irritation. If heated product contacts the eye,
thermal burns may result.
Skin contact: Product may cause skin irritation. When it is heated, this product may
cause thermal burns.
Inhalation: Exposure to oil mists/vapours/fumes may cause respiratory tract
irritation. Heating this product may release harmful vapours. Inhalation of
mists/fumes/vapours generated by heating this product may cause respiratory tract
irritation with throat discomfort, coughing and difficulty breathing.
Ingestion: Ingestion of large quantities may result in gastrointestinal disturbances
including irritation, nausea and diarrhea. Aspiration in to lungs may cause severe
damage, including chemical pneumonitis and pulmonary edema.
First aid measures:

Eye contact: Immediately flush eyes with flooding amounts of cool, low pressure
water for at least 15 minutes. If irritation persists, get medical attention. If hot
product contacts eye, flush with water for 15 minutes and seek medical attention
immediately.
Skin contact: In case of skin contact, wash immediately with soap water. If irritation
develops or persists, get medical attention. If hot product contacts skin, cool under
running water and get medical attention. Launder contaminated clothing before
reuse.
Inhalation: Move person to non-contaminated air. If affected person is not breathing,
apply artificial respiration. Seek medical attention.
Ingestion: If swallowed, contact a physician or poison control centre

immediately. DO NOT induce vomiting unless directed to do so by medical
personnel.
Note to Physician: Provide general supportive measures and treat symptomatically.

In case of ingestion, the decision of whether or not to induce vomiting should be
made by the attending physician. If burn is present, treat as ant thermal burn.
If victims of chemical over exposure are taken for medical attention, give a
copy of the label or MSDS to the physician/health professional.
Fire & Explosion Data:

Flammability of the product : Non flammable
Flammable limits : Not available
General fire hazards; Product is not considered combustible. If heated above its flash
point in the presence of air, product can support combustion. Porous material such
as rags, paper, insulation or organic clay may spontaneously combust when wetted
with this material. If mist is generated, minimum flash point may be reduced.
Hazardous decomposition products: Smoke, carbon monoxide, carbon dioxide, water,
trace quantities of sulphur oxides and other normal products of combustion.
Extinguishing Media: Carbon dioxide, dry chemical or water. Avoid using direct
stream of water
Fire fighting equipment and instructions: Wear full protective clothing, including self
contained positive pressure/pressure demand breathing apparatus, helmet, &
78
protective clothing. Use water spray to cool fire exposed containers and to protect
personal.

Containment: Contain the discharged material. Do not allow product to enter sewer
or man ways. Check with local & state environmental agencies for guidance.
Clean up procedure: Spills may present slipping (physical) hazard. Wear appropriate
protective equipment and clothing during clean up. Avoid skin & eye contact. Absorb
spill with inert material. Shovel material in to appropriate container for disposal.
Thoroughly wash spill area with eater after clan up.
Water spill: product is regulated as oil under the clean water act. Follow all
applicable regulations. Follow all applicable regulations. Follow all local, state,
federal and provincial regulations for disposal.
Evacuation Procedure: Isolate are. Keep unnecessary personnel away. In case of
large spills, follow all facility emergency response procedure.
Special Instructions: Remove soiled clothing and launder before reuse. Avoid
excessive skin contact with spilled material. Wear appropriate personnel protective
equipment.
Handling & Storage:

Handling: Avoid prolonged or repeated skin contact with this material. Wash
thoroughly after handling. Avoid inhalation of mists/vapours/fumes. Keep this
product from heat, sparks, or open flame. Do not use air pressure or apply heat with
open flame to remove contents of drum. After emptied, drum may retain solid, liquid
and/or vapour residues. Continue to observe all precautions on label as if drum were
full. Do not cut, puncture, torch, or weld on near the emptied drum. Do not use for
other purposes. Never heat, drink or smoke in work areas. Practise good personal
hygiene after using this material, especially before eating, drinking smoking, using
the toilet or applying the cosmetics.
Storage: Store at ambient temperature and atmospheric pressure. Porous material

such as clothing, rags, paper, insulation or organic clay may spontaneously combust
when wetted with this material.
Exposure Control/Personal protection:

Engineering Controls: Provide local exhaust and general ventilation systems to
maintain airborne concentrations below OSHA, ACGIH and manufactures
recommended exposure limits. Local exhaust ventilation is preferred because it
prevents contaminant dispersion in to work areas by controlling it at its source.
Local exhaust ventilation to effectively remove and prevent build up of mists/
vapours/fumes generated from the handling of this project.
Personal protection:
Eye/Face: Wear chemical goggles and face shield if splashing is possible. Ensure
compliance with OSHA’s personal protective equipment (PPE) standard for eye and
face protection, 29 CFR1910.133.
Skin: Use impervious gloves. Work clothing sufficient to prevent all skin contact
should be worn, such as coveralls and long sleeves. For heated & molten product,
use any type thermal insulating gloves and other clothing as necessary to protect
from thermal burns.
79
Respiratory: Gas/vapours: Suitable respirators to be used. For concentrations above

the TLV and/or PEL but less than 10 times these limits, a NIOSH approved half face
piece respirator equipped with appropriate chemical cartridges may be used.
General: Eye wash fountains & Emergency showers are recommended. Launder
contaminated clothing before reuse. Use good industrial hygiene practices in
handling this material.

Physical state & Appearance : Liquid
Odour : Fatty Acid (Slight)
Colour : Clear yellow to amber
Molecular weight : Not applicable
pH : Not applicable
Boiling Point : >260°C (500°F)
Specific Gravity : <1 (Water=1)
Relative Density/Sp.Gr : 0.88-0.93 @ 15.6°C
Vapour Density : Not available
K. Viscosity @ 40°C : 7-22cSt
Solubility (Water) : Negligible
Flash Point : ≥62°C
Pour Point : ≤ 0°C
Acid No. (per ASTM D-465) : ~193
Stability & Reactivity Data:

Chemical stability: The product is stable
Conditions to avoid: Avoid strong oxidising agents. Avoid prolonged contact with
porous materials.
Incompatibility: This product may react with strong oxidising agents.
Hazardous Decomposition Products: None, Except extreme high temperatures may
lead to decomposition, releasing fumes containing Carbon Monoxide, Carbon
Dioxide, Water, trace Sulphur Oxides, and/or hydrocarbons of varying molecular
weights.
Hazardous Polymerisation: Will not occur.
Toxicological information:
Toxicity to Humans: Contact may cause skin or eye irritation. Exposure to oil mists,
fumes, vapours may cause respiratory tract irritation with throat discomfort,
coughing and difficulty breathing. No carcinogenic effects.
Ecological information:
Ecotoxicity: When spilled, this product may act as an oil, causing a film, sheen,
emulsion, or sludge at or beneath the surface of a body of water.
Disposal consideration:
Water Disposal: wasters must be tested using methods described in 40 CFR 261 to
determine if it meets applicable definitions of hazardous waste. Dispose of water
material according to Local, state, Federal and Provincial Environmental Regulations.
80
 Corrosion Inhibitor (SR 1200-Dorf Ketal):
Description: SR 1200 is an oil soluble filming amine for application in overhead

systems.
Uses: SR 1200 is especially effective in Crude oil distillation units overhead where
corrosion is in form of HCL, H2S, Sox.
Features: SR-1200 is a good oil soluble filming amine with very good filming
properties.
Dosage: The dosage will vary depending on the severity of the corrosion problem.
The usual dosage range is 3-5 wt. Ppm for continuous treatment. Under unusual
conditions dosage may be high as 15 wt. Ppm.
SR 1200 can be injected continuous as a neat solution or it may be diluted with dry
solvents when SR 1200 is fed neat to a stream having a temperature above 200°F.
Benefits: Exhibits good corrosion control action by forming a persistent film.

Effective over a wide pH range. SR 1200 Corrosion inhibitor has demonstrated
performance at pH’s less than 2.0. Very well soluble in liquid Hydrocarbons, which
enhances distribution. Does not contain any metals or halogens, and Nitrogen is less
than 3%. So refinery catalyst will not be harmed. Exhibits good dispersancy
characteristics, prevents under deposit corrosion.

Type of Use : Corrosion Inhibitor
Composition/Information on Ingredients:
Component Name : Range
Heavy aromatic distillate : <30-60%
Imidazoline Derivative : <20-50%
1,2,4 trimethylbenzene : <3%
Xylene : <3%
Naphthalene : <2%
Ethyl Toluene : <2%
Cumene : <2%
1-Ethyl-2-methyl-benzene : <1%
1- Methyl-4-ethylbenzene : <1%
81
Hazards Identification:
Skin Contact:
 Frequent or prolonged contact may irritate and cause dermatitis.
 Low order of toxicity
 Skin contact may aggravate an existing dermatitis condition
Eye Contact: Slightly irritating but does not injure eye tissue.
Ingestion:
 Small amounts of this product aspirated in to respiratory system during
ingestion or vomiting may cause mild to severe pulmonary injury, possibly
progressing death.
 Minimal toxicity.
Inhalation: High vapour/aerosol concentrations (greater than 1000ppm) are irritating
to the eyes and the respiratory tract, may cause headaches, dizziness, anesthesia,
drowsiness, unconsciousness, and other central nervous system effects including
death.
First Aid Measures:

Eye Contact: Rinse immediately with plenty of water for at least 15 minutes. In case
of eye irritation, seek medical attention.
Skin Contact: Wipe with absorbent paper or textile towels. Wash off with soap and
plenty of water. Do not use organic solvents. In case of dermatitis, seek medical
attention.
After Inhalation: Move to fresh air. In case of irritation of respiratory system or

mucous membranes, indisposition, prolonged exposure, seek medical attention.
After ingestion: immediately give plenty (>500ml) of water (if possible charcoal
slurry). In case of spontaneous vomiting be sure that vomitus can freely drain due to
danger of suffocation. Give water repeatedly. Artificial induction of vomiting should
be restricted to first aid staff. Give nothing by mouth in cases of unconsciousness or
convulsion. Seek medical advice.
Fire fighting measures:

Suitable Extinguishing media: Water spray, Foam, Carbon Dioxide, Dry Powder.
Fire & Explosion Hazards: Contaminated water from fire hoses or sprinklers, etc.
Must be prevented from draining in to watercourses, sewers or the ground water.
Sufficient measures must be taken to retain water used for extinguishing.
Contaminated water & soil must be disposed of in conformity with local regulation.
Special protective Equipment: Water full protective clothing. Wear self contained
breathing apparatus.
Flash Point: >60°C
Accidental Release measures:

Personal Protection: Avoid contact with Skin, eyes & clothing.
Environmental Precautions: Do not flush in to surface water, sanitary sewer or
ground water system.
Clean Up: Soak up with inert absorbent material (e.g. sand, silica gel, acid binder,
universal binder saw dust). Collect the spilled product in to containers, which tightly
sealed & properly labelled.
82
Water Spill: Eliminate sources of ignition. Warn occupants and shipping in

surrounding & down ward areas of fire and explosion hazard and request all to stay
clear. Consult an expert on disposal of recovered material and ensure conformity to
local disposal regulations.
Handling & Storage:

Electrostatic Accumulation Hazard: Yes, use proper bonding and/or grounding
procedure.
Storage & handling: keep container closed. Handle and open containers with care.
Store in a cool, well ventilated place away from incompatible material. Do not handle
or store near an open flame, heat or other sources of ignition. Protect material from
direct sun light. Material will accumulate static charges which may cause an
electrical spark (ignition source). Use proper bonding and/or grounding procedures.
Do not pressurise, cut, heat, or weld containers. Empty product containers may
contain product residue. Do not reuse empty containers without commercial cleaning
or reconditioning.
Exposure control/ Personal Protection:

Exposure controls: The use of local ventilation is recommended to control process
emissions near the source. Laboratory samples should be handled in a lad hood.
Provide mechanical ventilation of confined spaces.
Personal Protection Equipment: For open systems where contact is likely, wear
safety glasses with side shields, long sleeves & chemical resistant gloves. Where
contact may occur, wear safety glasses with side shields.
Eye Protection: Suitable goggles or face protection.
Hand Protection: Protective gloves.
Skin & Body protection: Working clothes, closed foot wear.
Respiratory protection: In case of insufficient ventilation wear suitable respiratory
equipment.
Physical & Chemical properties:

Form : Liquid
Odour : Aromatic
Flash Point : >62°C
Relative density/Sp. Gr. : 0.90-1.05@15.6°C
Kinematic Viscosity : 2-16cSt@40°C
Solubility : ND
Colour : Yellow to dark amber liquid
Stability:
Stability: Stable
Hazardous decomposition Products: Oxides of carbon, Oxides of Nitrogen (NOx),
Toxic gases and vapours.
Conditions/Materials to avoid: Strong acids, Strong bases & Strong oxidising agents.
Static discharges.
Provisions related to waste: Residual chemical should be disposed by incineration or
by other modes of disposal in companies with local legislation.
83
Disposal information: Contaminated packaging material should be treated equivalent

to residual chemical. Clean packing material should be subjected to waste
management schemes (recovery recycling, reuse) according to local legislation.
 Antifouling agent (SR 1321-Dorf Ketal):

Type of Use : Anti foulant
Identification of the Company : Dorf Ketal chemicals India Pvt. Ltd
Composition:
Ingredient : Wt%
Amine polymer : 45-55%
Aromatic Hydrocarbon : 40-55%
1,2,4-Trimethylbenzene : <5%
Naphthalene : <3%
84
Hazard Identification:
Emergency over view: This brown liquid may cause irritation of the skin, eyes and
respiratory tract. The product is combustible and toxic vapours may be given off in
flare.
Potential Health Effects:

Primary Routes of Exposure: Contact with skin, eyes and product vapour inhalation.
Product ingestion is unlikely to occur if proper safety/hygiene procedure are
followed.
Skin Contact: May cause skin irritation. Prolonged or repeated exposure may cause
dermatitis or an allergic skin reaction
Eye contact: May cause eye irritation.
Ingestion: This product is considered to have a low order of oral toxicity.
Inhalation: Inhalation of the product vapours or mist may cause irritation of the
respiratory tract. Inhalation of high vapour concentrations may cause headache,
nausea, dizziness & central nervous system depression.
Target Organ: May cause central nervous system disorder (e.g. narcosis involving a
loss of co-ordination, weakness, fatigue, mental confusion, and blurred vision) and
/or damage
First Aid Information:

Skin Contact: Remove from skin Emergency. Apply a generous amount of
waterless hand cleaner (such as GOOP, GoJo or similar products) to the affected
area. Rub briskly onto the skin, on and around the affected area. Remove the mixture
of cleaner-product with paper towels or clean dry rags. Repeat the entire procedure,
then wash the skin with a mild soap, rinsing with warm water. If irritation develops,
obtain medical attention.
Eye contact: Flush with water at least 15 minutes. If irritation occurs, obtain medical
attention.
Ingestion: Do not induce vomiting. Obtain immediate medical attention.
Inhalation: Remove affected person to fresh air. If respiratory problems develop,
obtain medical attention.
Note to Physician: Activated charcoal slurry taken within 30 minutes of product
ingestion may reduce the toxicity of the chemical. A5:1 weight of charcoal to
material ingested is the recommended dosage. Activated charcoal should not be
considered as an antidote. Normal symptomatic treatment is recommended with or
without the administration of activated charcoal.

Large Spill: Standard hydrocarbon spill procedures apply to this product. Remove all
sources of ignition. Isolate the affected areas. Confine entry in to the affected area
to those persons properly protected. Stop leak at the source. Cut off and redirect
surface run off by trenching or drinking.
85
Small spill: Wear protective equipment. Absorb spilled product using commercial oil
absorbent soaking up as much product as possible. Product should be disposed of in
accordance with all applicable government regulations.
Handling & Storage:

Store in tightly closed, properly labelled containers in a cool, well ventilated area
away from all ignition sources. Store out of direct sunlight. Wear appropriate
protective equipment. Avoid inhalation of product vapours or mist. Never use a
welding or cutting torch on or near drum (even empty) because vapours from the
material 9even residue) can ignite explosively.
Exposure controls & Personal protection

Respiratory protection: Where natural ventilation is inadequate, use mechanical
ventilation.
Skin protection: Gloves, footwear, coveralls and/or apron as necessary to prevent
repeated or prolonged skin contact any.
Eye protection: Chemical goggles or face shield as necessary to prevent eye
contact.

Appearance : Yellow to Amber liquid
Odour : Hydrocarbon Apparent
Pour point : Below 0°C
Sp. Gr. : 0.89-0.92@15.6°C
Solubility in water : Insoluble
Boling point: 363°F (184°C) Vapour Pressure : <0.1mmHg@68°F
Stability:
Stability: Stable
Condition to avoid: Thermal decomposition. Exposure to heat, light sparks and open
flame.
Hazardous Decomposition products: The product itself does not readily decompose
unless subject to extreme temperature or chemical conditions. CO, CO2, NOx may be
generated in the event of incomplete burning.
Hazardous polymerisation: Will not occur.
In compatible material: Oxidising agents
Disposal Information:
Waste material, including liquids, contaminated absorbent and material from spill
cleanup procedures, must be handled in accordance with all applicable government
regulations. It is up to the user of this product to determine the hazardous associated
with any waste material generated. Recommended disposal methods include
incineration for contaminated liquids & solids.
86

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Mangalore Refinery and Petrochemicals Ltd, Mangalore Doc No.

DHDT Unit – Phase-3 - Operating Manual F … ….

Safety Aspects & MSDS

3. Safety Gadgets/provision in the unit

4. Precautions & Procedures for handling hazards

 Mechanical Hazards, Plant Maintenance

1.1 Safety recommendations

Plant safety features

S. IPF Tag No Service

 IPF: Instrument Protective Function

1.2 Reactor Protection

1. A pressure versus temperature diagram indicating where it is possible to

1.3 Hazardous and toxic materials

2.1 General remarks

In case of unconsciousness, artificial respiration should be applied.

Smoking must be forbidden in all parts of the DHT plant.

2.2 Potential hazards

2.3 Toxicity of gases and liquids

 High temperature media

 Explosives and flammable media

2.4 Equipment for protection of personnel

7. SCBA for streams containing H2S sampling.

Hand-operated fire extinguishers, fire carpets and emergency showers should be

3. Safety Gadgets/provision in the unit

3.1 Fire Water System

Fire protection systems considered

System considered and units / area / equipment to be protected

 Fire Water Main Ring:

Fire hydrant system Equipment Details:

 Double headed Hydrants : 23

 Fixed water monitor:

 Fixed water spray system

2. HP separator (FA - 33304)

Automatically operated, fixed medium velocity water spray system considered

Nature of design for MVWS / HVWS system:

Spray systems for different equipment may be grouped according to convenience of

a. Hydro test pressure:

b. Equipment considered with water curtain system

Following fired heaters are covered with water curtain system:

3.2 Fire extinguishers

Location of DCP Extinguishers (5 Kg) : 25 No.

1) D-1: DC-33301, 3.7 meter height.

11)D-11: TS-1 (6.5 mt), West side of EA-33304.

35)D-35: Near GA-33323/GA-33325A

Location of DCP Extinguishers (50 Kg) : 14 No.

1) D-1: SE corner of GB-33303A

3.3 Gas detection system

1. Light hydrocarbon pumps in process unit.

S. Tag No. Type Equipment Location

4) XL-333504 - - Near FA-33320 on pipe rack

3.4 Plant communication system:

Location of equipments of PA system in MRPL-DHT plant area:

1) 333-PA-801-001 : Near to GA-33311A

8) 333-PA-801-008 : Near to BA-33302

 Fire call point:

 333-T-06: In-between EA-33310 & EA-33314B

3.5. Emergency Power supply

3.6 Environmental aspects

 Monitoring of pollutants in flue gas

 Liquid Effluent Discharge

Note-2 (HR-198): Before draining any Hydrocarbon to CBD, Operator as to

In order to protect the system / equipment in case of abnormal situations as