Dakhni Gas Processing Plant/ Field

Oil & Gas Development Company Ltd.

HEALTH, SAFETY & ENVIROMMENT PROCEDURE

PROCEDURE

CHEMICAL HANDLING
SAFETY

Document Number DGF-HSE-001

Document Issue Number
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TABLE OF CONTENTS
DOCUMENT CONTROL:...........................................................................................................3
DISTRIBUTION LIST:................................................................................................................3
HISTORY OF AMENDMENTS:.................................................................................................4
6.1.2 Corrosives Chemicals:....................................................................................................9
6.1.3 Chemical asphyxiates:....................................................................................................9
6.1.4 Irritant gases and vapours:............................................................................................9
6.1.5 Carcinogens and suspect carcinogens:..........................................................................9
6.1.6 Infectious substances:.....................................................................................................9
6.2 Material Safety Data Sheets (MSDS)..............................................................................10
Chemical identification..........................................................................................................10
Hazardous ingredients...........................................................................................................10
Physical data..........................................................................................................................10
Fire and explosion data..........................................................................................................10
Health hazards.......................................................................................................................10
Reactivity data.......................................................................................................................10
Spill and leak procedure........................................................................................................10
Special protection..................................................................................................................11
Special precautions................................................................................................................11
Labels and chemical identification........................................................................................11
6.2.1 MSDS Master File/Listing............................................................................................11
6.3 Packaging and Labeling...................................................................................................11
6.3.1 Warning signs:...............................................................................................................12
6.4 Storage (General requirements)......................................................................................14
6.4.1 Ventilation......................................................................................................................15
6.4.2 Wiring............................................................................................................................15
6.5 Transport and Transferring of Chemical:.....................................................................15
6.5.1 Personal protective equipment (PPE):........................................................................15
6.6 Spills and Waste disposal:................................................................................................16
6.7 Disposal of chemicals waste:............................................................................................16
6.8 System Evaluation............................................................................................................16
ASSOCIATED DOCUMENTS:.................................................................................................17
APPLICABLE DOCUMENTS:.................................................................................................17

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DOCUMENT CONTROL:

Developed by Reviewed By Approved By

HSEQ Dakhni I/C Q.A & Q.C Lab. Plant Manager

DISTRIBUTION LIST:
Sr. No. Copy Holder Position Signature
(Section / Department)
01 Plant Manager Location Incharge
02 Process I/C Process / Reliever
03 Production I/C Production / Reliever
04 QA & QC Lab I/C Lab / Reliever
05 Store I/C Store / Reliever
06 Medical I/C Medical / Reliever
07 HSEQ I/C HSEQ / Reliever

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HISTORY OF AMENDMENTS:

Rev. Date Initiated By Section Nature of Amendment Done By

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1. PURPOSE
The purpose of this procedure is to ensure the safe handling, use and disposal of all chemicals.
2. SCOPE
This procedure is applicable to the plant / residential camps, well sites and all other associated places
under the working scope / jurisdiction of Quality Control section of the Dakhni Gas processing Plant/
Field .
3. DEFINITIONS
Bioaccumulate: This term is used to describe the process of concentration of a chemical substance in
biological tissue, relative to the concentration in the environment.
Chemical Agent: A chemical substance, whether pure or in mixture with other substances.
Combustible liquid: Any liquid having a flash point at or above 100ºF (37.8ºC).
Chronic: Chronic toxicity is a property of a substance that has toxic effects on a living organism,
when that organism is exposed to the substance continuously or repeatedly.
Ecosystem: The term used to describe the physical and biological components that make up an area.
Ecotoxicity: The term used to describe the property of some chemical substances released to the
environment causing toxicity to several biological components of ecosystem.
Environmental Risk: It is a measure of the potential threats to the environment, which combines the
probability that an event may occur, which may cause degradation of the environment with the
severity of that degradation.

Exposure Limit (EL) : The airborne concentration of chemical agents and levels of physical agents
to which workers may be repeatedly exposed, day after day, without adverse effect.

Flammable liquid: any liquid having a flash point below 100ºF (37.8ºC). For e.g oxygen, acetylene
and propane gas.
Flammable Range and Lower and Upper Flammable Limits (LFL or UFL) When vapors of a
flammable or combustible liquid are mixed with air in the proper proportions in the presence of a
source of ignition, rapid combustion or an explosion can occur. The proper proportion is called the
flammable range and is also often referred to as the explosive range. The flammable range includes
all concentrations of flammable vapor or gas in air, in which a flash will occur or a flame will travel if
the mixture is ignited. There is a minimum concentration of vapor or gas in air below which
propagation of flame does not occur on contact with a source of ignition. There is also a maximum
proportion of vapor in air above which propagation of flame does not occur. These boundary-line
mixtures of vapor with air are known as the lower and upper flammable limits (LFL or UFL)

Flash point: the minimum temperature at which a liquid gives off vapor within a test vessel in
sufficient concentration to form an ignitable mixture with air near the surface of the liquid. The flash
point is normally an indication of susceptibility to ignition. Flash point is selected as the basis for
classification of flammable and combustible liquids because it is directly related to a liquid's ability to
generate vapor, i.e., its volatility. Since it is the vapor of the liquid, not the liquid itself that burns,
vapor generation becomes the primary factor in determining the fire hazard. The expression "low
flash - high hazard" applies.

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Health Hazard: This is the potential of an agent to cause harm to health. These agents may be
biological, chemical, physical, ergonomic or psychological in nature. Hazards are normally classified
according to the severity of their adverse health effects.
Health Risk: Health risk is the combination of likelihood that harm to health may occur (which is
related to exposure) multiplied by the severity of health effects (hazard).

Leukaemia: is a type of cancer of the blood or bone marrow that is characterized by an abnormal
increase of white blood cells.
MSDS: Material Safety Data Sheet. Information sheet provided by the supplier of chemical product
which provides details on HSE risks.
Mutagen: Chemical agent that causes cell mutation.
Permissible Exposure Limit (PEL):
4. REFERENCES

 OGDCL HSE System Manual (Section 4, 12 & 14),

 OHSAS STANDARD (Clause 4.4.6),
 OSHA Standard (1910.106),
 Pakistan Environmental Protection Act 1997,
 Mines Act 1923,
 Factory Act 1934,
 Oil & Gas Safety in Drilling & Production Regulation 1974,
 NFPA 30, 704, 70E,
 Best Industrial Practices / Guidelines,

5. ROLES AND RESPONSIBILITIES

5.1 In-charge process / Incharge Lab
 In-charge process / Incharge lab has the overall responsibility to implement this procedure in
their respective areas.
 They are responsible for ensuring that MSDS information is effectively disseminated to the
workforce, and that it is used to safely store, handle, use and dispose off any chemicals.
 Knowing the location of MSDS and the format in which they are maintained.
 Ensure that MSDS are available for all chemicals prior to being transferred to Worksite;
 Keep study / reading MSDS and trained the worker about MSDS.
 Maintain a log of all chemicals (storage locations, quantities, etc) at the Jobsite; and
 Ensure that system is complying with protection methods relating to chemical hazards.
 Ensuring the provision of periodic review of this procedure.
5.2 HSE In-charge shall:
 Ensuring that all HSE measures are taken before execution of jobs.
 Ensuring that HSE risk register and JHA are followed while performing the activities.
 Ensuring the proper implementation and execution of the procedure with related formats.
 Periodically checking presence of Fire fighting equipment in related areas.
 Identifying hazardous conditions in all area for controlling any deviation from HSE policy
and procedures through periodic HSE inspection.
 Ensuring an effective implementation of corrective and preventive actions against any non-
conformance and recommendation highlighted in HSE audits.

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 Monitor and close out any control actions, training, and workplace monitoring and worker
health surveillance identified in the risk assessments.
 Improving the chemical safety awareness amongst incharges, officers and workers by
participating in or conducting HSE training programmes.
5.3 Material Management Section shall:
 Maintain the inventory of all chemicals that are kept at the Worksite, and update the list of
inventory on a monthly basis.
 Maintain MSDS of hazardous chemicals kept in the store and maintain its inventory.
 Ensuring that adequate resource are available and employed for effective storage of
chemicals.
 Ensuring that minimum inventory level of all PPE(s), safety devices & Fire Extinguishers are
available.
 Handling the chemical drum / container with care so that it should not fall / leaked on
ground / feet.
 Ensuring the smoking in chemical storage area is completely restricted.
 Ensuring that adequate ventilation is provided in the chemical working / storage area.
 Ensuring the availability of proper drainage for any discharge or over spill.
5.4 Contractors and suppliers:
 Contractors bringing in and using chemicals on site submit the relevant MSDS one month
prior to arrival of the hazardous chemical at field. Chemical suppliers / manufacturer provide
MSDS along with the chemicals.
 All employees and contractors at sites shall be responsible for implementation of the
procedure to minimize the risk of injury to themselves, others and the environment.

6. Procedure
6.1 General
This procedure covers the general characteristics of the chemicals that are used at OGDCL
Dakhni Gas processing Plant/ Field s. There are two primary hazards associated with flammable
and combustible liquids: Explosion and Fire. In order to prevent these hazards, this procedure
addresses the primary concerns of design and construction, warning, ventilation, ignition sources,
and storage.
6.1.1 Hydrocarbons
These substances exist in both liquid and gaseous form. They are in the work place in the form of
fuels, lubricants, and fuel gases. They are also found in many other chemicals such as solvents,
thinners and paints. Inhalation of hydrocarbon vapours may cause headaches, dizziness, or in
extreme cases, suffocation. Skin and / or eye contact with the liquid can cause irritation. Chronic
inhalation studies with light hydrocarbon components have shown kidney damage and kidney
cancer.
6.1.1.1 Hydrocarbon Classification: According with flash points, hydrocarbons are classified as:
Flammable liquid: Any liquid having a flash point below 100ºF (37.8ºC). For e.g oxygen,
acetylene and propane gas. Flammable liquids shall be known as Class I liquids. Class I liquids
are divided into three classes as follows:
Class IA shall include liquids having flash points below 73ºF (22.8ºC) and having a boiling point
below 100ºF (37.8ºC). For eg. Dimethyl ether, Diethyl ether.
Class IB shall include liquids having flash points below 73ºF (22.8ºC) and having a boiling point
at or above 100ºF (37.8ºC). For e.g Ethanol, Gasoline
Class IC shall include liquids having flash points at or above 73ºF (22.8ºC) and below 100ºF
(37.8ºC). For e.g turpentine and n-butyl acetate
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Combustible Liquid: Any liquid having a flash point at or above 100ºF (37.8ºC). Flash points
above 37.8 degrees Celsius Combustible liquids shall be divided into two classes as follows:
Class II liquids shall include those with flash points at or above 100ºF (37.8ºC) and below 140ºF
(60ºC). For e.g Kerosene and camphor oil.
Class III liquids shall include those with flash points at or above 140ºF (60ºC). For e.g phenol,
naphthalene. Class III liquids are subdivided into two subclasses:
Class IIIA liquids shall include those with flash points at or above 140ºF (60ºC) and below 200ºF
(93.3ºC).
Class IIIB liquids shall include those with flash points at or above 200ºF (93.3ºC).
When a combustible liquid is heated to within 30ºF (16.7ºC) of its flash point, it shall be handled
in accordance with the requirements for the next lower class of liquids.

6.2.2 Classes of Flammable and Combustible Liquids:

6.1.2 Corrosives Chemicals:

Corrosive chemicals are those that can cause visible damage or irreversible changes to any part of
the body it comes in contact with. They can burn eyes and skin and result in permanent damage.
Well-known corrosives are sulphuric acid and caustic (sodium hydroxide). Other less well-known
corrosives include phenol and hydroxides. All corrosive materials shall be handled with extreme
caution and with appropriate protective equipment, such as gloves, chemical goggles and face
shields. If contact does occur, flush the affected area with water for 15 minutes, then seek medical
attention.
6.1.3 Chemical asphyxiates:
These are chemicals which can cause suffocation by chemically restricting the intake of oxygen
or by respiratory paralysis. Two such chemicals are carbon monoxide and hydrogen sulphide.
Other forms of asphyxiates are the inert gases such as nitrogen and argon. Most of these are
odourless.
6.1.4 Irritant gases and vapours:
Gases and vapours which are irritating (and in some cases severely irritating) to the skin, eyes,
and respiratory track are considered irritant gases. Examples of these gases are chlorine,

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ammonia and sulphur dioxide. All these gases have very pungent odours and will immediately
cause irritation and discomfort to the eyes, skin, or respiratory track.
6.1.5 Carcinogens and suspect carcinogens:
Chemicals which have the potential or suspected potential to cause cancer are known as
carcinogens. Suspected carcinogens are those chemicals which have been shown to cause cancer
in humans.
Benzene is a carcinogen which can cause leukaemia. Benzene can be found in hydrocarbon fuels.
Some refractory materials may contain known or suspected carcinogens. Isocyanides are irritants
and carcinogen/ Asbestos is a known carcinogen and has been linked to lung cancer.

6.1.6 Infectious substances:

They are the substances which contain bacteria, viruses, parasites, fungus, and genetically
engineered organism, known or reasonably believed to cause diseases to the humans or animals
(e.g. medical waste from Worksite Clinics / first aid stations).
6.2 Material Safety Data Sheets (MSDS)
MSDS Contents:
MSDSs shall be used as source for determining whether or not a chemical or substance is
hazardous. The hazard information is based on the International Standard for Product
Information i.e Safety Data sheet for Chemical Products.
Material Safety Data Sheets provide the following information:

Chemical identification
The first section helps identify the chemical by name, trade names, and the chemical
manufacturer

Hazardous ingredients
This section lists what is in the chemical mixture that can be harmful. It also lists the
concentration of the chemical ingredient and the exposure limit to which one can safely be
exposed.

Physical data
This section describes the chemical’s appearance, colour, and other physical characteristics such
as boiling point, volatility, and vapour pressure.

Fire and explosion data

This section describes the temperature at which the chemical ignites; this is called its flash point.
Flammable materials have flash points below 37.8 degrees Celsius and combustible materials
have flash points between 37.8 and 61 degrees Celsius.
This section of the MSDS also lists the proper extinguishing agents to be used to put out the fire.

Health hazards
This section lists symptoms of over-exposure. It also provides first-aid emergency procedures in
case of overexposure.

Reactivity data
This section describes if the chemical reacts with other chemicals, water, or certain conditions
such as temperature. Incompatibility information lists the materials, such as water, that causes
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the chemical to burn, explode, or release dangerous gases. Instability describes environmental
conditions, such as heat, that cause a dangerous reaction.

Spill and leak procedure

This section explains what to use to clean up a spill, and the protective equipment that should be
used. This section also identifies how to dispose off the chemicals safely.

Special protection
This is a listing of any personal protective equipment needed to work safely with the chemicals.
If protective equipment is needed, this section lists the specific types that are recommended.

Special precautions
This section lists other special precautions to follow. This includes other health and safety
information not provided in any other section.

Labels and chemical identification

Each container of hazardous chemicals in the work place shall be labelled, tagged, or marked
with the identity of hazardous chemicals contained in them. It shall show hazard warnings
appropriate for employee protection. The hazard warning can be any type of message, words,
pictures, or symbols which convey the hazards of the chemical(s) contained in the container.
6.2.1 MSDS Master File/Listing
Concerted section maintains a file of all MSDS in alphabetical order by common or trade name.
This file should be made available for the use of all supervisors and employees for determining
hazards associated with these chemicals, and precautions to be taken when working with them.
6.3 Packaging and Labeling
OGDCL Dakhni management shall comply with the Labelling / Warning requirements given in
this document. The responsibility for ensuring that this requirement is met rests with the
person(s) originating the order for the chemical, the person(s) receiving the chemical, and the
user of the chemical.
Contractor shall not bring in any container, sack or other packing material to the Worksite
without correct identification of its content.
The generic control measures for packaging and labelling any chemical are given as follows,
Each container of chemicals at the Worksite is labelled, tagged, or marked with the identity of
hazardous chemical contained therein, and show hazard warnings appropriate for employee
protection. The hazard warning label includes uses of words, pictures and symbols in order to
convey the hazardous status of the chemical(s) in the container.
Labels shall be legible, in English (plus other languages, as required), and prominently displayed.
The word, term, or phrases that are used to identify the hazardous chemical(s) on the label are
taken from relevant MSDS.
Signs, placards, process sheets, batch tickets, operating procedures, or other such written
materials may be used in lieu of affixing labels to individual stationary process containers.

6.3.1 Warning signs:

NFPA (National Fire Protection Association)

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OGDCL Dakhni Gas processing Plant/ Field use the NFPA system for warning labels. This is a
diamond diagram, which is divided into four color coded sections:
Red - flammability information;
Blue – health information;
Yellow - reactivity information; and
White - special information.

Each of the three colored areas in the NFPA fire diamond has a
box in which the degree of hazard can be written. The
degree of hazard is given by these numbers:
Number Degree of Hazard
4 Extreme
3 Serious
2 Moderate
1 Slight
0 Minimal

An explanation of each of the hazards for each section is given as follows:

Health (blue)
4 On very short exposure could cause death or major residual injury even
Extreme
though prompt medical treatment is given.
Highly toxic material A known or suspected human carcinogen, mutagen or teratogen.
3 Serious May cause serious temporary or residual injury on short term exposure
even though prompt medical attention is given.
Toxic material
A known or suspected small animal carcinogen, mutagen or teratogen.
2 Moderate
Intense or continued exposure could cause temporary incapacitation or
Moderately toxic possible residual injury unless prompt medical treatment is given
material
1 Slight May cause irritation but only minor residual injury even without
treatment.
Slightly toxic material Recognized innocuous material when used with responsible care
0 Minimal No chemical is without some degree of toxicity.

Flammability (red)
4 Extreme
Flash point below 73 F (22.8 C)
Extremely
flammable
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3 Serious Vaporizes readily and can be ignited under almost all ambient conditions.
May form explosive mixtures with or burn rapidly in air.
Flammable
May burn rapidly due to self-contained oxygen.
May ignite spontaneously in air
Flash point at or 22.8 C but less than 37.8 C
2 Moderate Must be moderately heated or exposed to relatively high temperatures for
ignition to occur.
Combustible Solids which readily give off flammable vapours.
Flash point at or above 37.8 C but less than 93.4 C
1 Slight Must be preheated for ignition to occur.
Will burn in air when exposed at 815.5 C for 5 minutes.
Slightly
combustible Flash point at or above 93.4 C
0 Minimal Will not burn
Will not exhibit a flash point
Will not burn in air when exposed at 815.5 C for 5 minutes.

Reactivity (Yellow)
4 Extreme Can explode or decompose violently at normal temperature and pressure
Can undergo a violent self-accelerating exothermic reaction with common
materials or by itself
May be sensitive to mechanical or local thermal shock at normal temperature
and pressure
3 Serious Can detonate or explode but requires a strong initiating force or confined
heating before initiation
Readily promotes oxidation with combustible materials and may cause fires
Is sensitive to thermal or mechanical shock at elevated temperatures.
May react explosively with water without requiring heat or confinement
2 Moderate Normally unstable and readily undergoes violent change but does not detonate.
May undergo chemical change with rapid release of energy at normal
temperature and pressure.
May react violently with water
Forms potentially explosive mixtures with water
1 Slight Normally stable material which can become unstable at high temperature and
pressure
0 Minimal Normally stable material which is not reactive with water

Special (White)

Water Reactive
Ox
Oxidizing Agent

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Radioactive

Poison

6.4 Storage (General requirements)

Chemical storage areas are properly secured (e.g. fence, locked doors, etc).
The floors of the storage areas are impermeable having secondary containment / drip tray to
accommodate the chemicals in case of spillage.
In every inside storage room, there shall be maintained an aisle at least 3 feet wide. Easy
movement within the room is necessary in order to reduce the potential for spilling or damaging
the containers.
Suitable fire control devices, such as small hose or portable fire extinguishers, shall be available
at locations where flammable or combustible liquids are stored.
Open flames and smoking shall not be permitted in flammable or combustible liquid storage
areas.
Spill kits) are kept in all hazardous chemical storage areas.
Flammable and combustible liquid storage areas are protected by automatic sprinkler or water
spray systems and hose lines.
Only approved containers and portable tanks may be used to store flammable and combustible
liquids meeting the storage requirements as per the respective MSDS. Maximum allowable sizes
of various types of containers and portable tanks are specified based on the class of flammable
and combustible liquid they contain. The international standard permits both metal and wooden
storage cabinets. Storage cabinets shall be conspicuously labeled, "Flammable - Keep Fire
Away."

6.4.1 Ventilation
Every inside storage room shall be provided with either a gravity or a mechanical exhaust
ventilation system designed to provide for a complete change of air within the room at least six
times per hour. Ventilation is vital to the prevention of flammable liquid fires and explosions. It is
important to ensure that air flow through the system is constant and prevents the accumulation of
any flammable vapors.

6.4.2 Wiring
Electrical wiring and equipment located inside storage rooms used for chemical shall be as per
the electrical hazard area classification.(REF. Electrical Safety Procedure).

6.5 Transport and Transferring of Chemical:

Transportation of hazardous substances at the Worksite shall be carried out in compliance with
the transportation requirements mentioned in the respective Material Safety Data Sheet. In all
cases the chemical being transported is clearly identified by warning signs.
Hazardous materials are packed in a good quality packing, capped and sealed properly to avoid
any spill or leak during loading / unloading and transport.
The choice of packing material should take consideration of the nature of the substance packed.
The exterior body of the packing and the interior coating or surface should be resistant to
vibrations.
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The type, quantity, quality and specification of hazardous material shall be written on labels to be
affixed to packages.
Moreover, the generic actions to be taken while transferring chemical are given as follows,
Flammable liquids shall be kept in covered containers when not actually in use.
Flammable or combustible liquids shall be drawn from or transferred into vessels, containers, or
portable tanks through a closed piping system, from safety cans, By means of a device drawing
through the top, or from containers or portable tanks.
Transfer operations must be provided with adequate ventilation. Sources of ignition are not
permitted in areas where flammable vapors may travel.
6.5.1 Personal protective equipment (PPE):
In addition to standard PPEs, OGDCL, provide all PPEs required by the MSDS to its workers.
This may include:
 Safety goggles;
 Full face shield;
 Respiratory protection and breathing apparatus;
 Chemical suits; and
 Rubber boots and gloves;
PPEs are available and used by all employees handling hazardous chemicals. Concerned
Incharges, ensures that all personnel using such equipments are adequately trained and proficient
in the use of such equipments.

6.6 Spills and Waste disposal:

Generic Action to be taken against Spill Control are given as follows,
 If spilled materials are flammable, eliminate sources of ignition from near the spill area.
Stop the source of the spill and contain the spill within as small an area as possible. If the
spill is small or minor, clean-up the spill by using spill control equipment.
 Proper spill control equipment includes fire blankets, spill control materials such as sand,
absorbent, neutralizer, and a spill control kit. A 100% wool fire blanket is an excellent
spill control device because it will contain and control a spill and its vapours. The blanket
will begin to absorb the liquid, contain the vapors, and will enable a person to walk over
the spill without slipping. Remember, acid spilled on a tile floor will make the floor very
slippery.
 Avoid inhalation of vapours by staying upwind.
 Use chemical-resistant personal protective equipment (PPE) during cleanup activities.
 Gasoline and its vapours are HIGHLY FLAMMABLE - remove sources of heat, sparks,
flame, friction, and electricity. Gasoline vapours may create an explosive atmosphere.
 Avoid being burned by hot oil.
 Restrict fires or open flames from the spill area.
 Refer to MSDS for special hazards associated with any spilled chemicals, especially for
reactivity with other materials in the spilled area.
 Spills of acids, caustics, or other dangerous chemicals outside of contained areas should
be diced with absorbent, clay or soil to prevent liquid from reaching storm sewers or
bodies of water.
 Concerned incharge (where the spill takes place) shall complete an Incident / Accident
Report and send it to Incharge HSE.
 Emergency Response / Emergency Evacuation Procedure shall be used in the case of
major emergency spill (REF. ERP Manual).
6.7 Disposal of chemicals waste:
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The disposal of any chemical waste shall be carried out in accordance with Waste Management
Procedure. Moreover, Hazard Identification & Risk Assessment and Environmental Aspect
Impact Analysis shall be considered while disposing of chemical waste.
6.8 System Evaluation
 Periodic HSE audit / inspection shall be conducted which includes the examination /
verification of effectiveness of the management and inspection activities related to
chemical Safety.
 Review of this procedure shall occur on every two year basis or depending upon the
decision taken in management reviews.
 Employees shall provide periodic training on this procedure to ensure that the purpose
and function are understood by employees and that the knowledge and skills required for
the execution of this procedure are acquired by employees.

ASSOCIATED DOCUMENTS:
 Chemical Register
 MSDS

APPLICABLE DOCUMENTS:

 HSE System Manual For Production Fields & Plant Functions

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