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September 2012
This publication has been developed to provide a clear, comprehensive and practical guide to all, aspects of chemical tank terminal activities, from basic design and layout to the ongoing safe and efficient operation, maintenance and management of the facility.
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The Bulk Liquid Chemical Handling Guide (BLCH) is the only publication of its kind in the world. The text and imagery within this title provide chemical, terminal and supply chain companies with valuable knowledge and insight into handling bulk liquid chemical products. BLCH follows the chapters of the CDI Terminal Inspection Report, furnishing guidance to terminal managers, employees and inspectors in addressing the management functions and technical operations of a bulk liquid chemical storage terminal. Acknowledging regional legislation and focused on Health, Safety, Environment and Security, the guide is a single international reference offering solutions and alternatives to achieve safe and efficient operational performance.
VOLUME I 1. Chemicals and their Classification 1.1 Introduction 1.2 Regulatory Considerations 1.3 Basic Chemistry 1.4 Chemical Gases 1.5 Petrochemical Products 1.6 The Polymer Industry 1.7 Oleochemicals 1.8 Some Common Liquid Products Requiring Bulk Storage 1.9 Implications of Chemical Characteristics 1.10 Naming and Numbering Chemicals 1.11 Chemical Classification Systems 1.12 Material Safety Data Sheets (MSDS) 1.13 Special Information or Product Specific Requirements References and Further Reading 2. Storage Tanks and Equipment 2.1 Introduction 2.2 Regulatory Considerations 2.3 Risk Assessment 2.4 Overview of Tank Types 2.5 Location and Layout of Tanks 2.6 General Tank Design and Construction 2.7 Pipework Systems and Pumps 2.8 Common Fittings and Fixtures 2.9 Earthing and Bonding 2.10 Gauging, Temperature Measurement and Sampling 2.11 Vapour and Emission Control 2.12 Bunds and Drains (also Referred to as Dikes) 2.13 Fire Safety 2.14 Operational Issues 2.15 Tank Cleaning 2.16 Inspection, Testing and Maintenance References and Further Reading 3. Product Transfer Equipment 3.1 Introduction 3.2 Regulatory Considerations 3.3 Risk Assessment 3.4 General Considerations 3.5 Pumps 3.6 Pipes 3.7 Valves 3.8 Hoses 3.9 Loading Arms 3.10 Couplings and Gaskets 3.11 Measuring Systems 3.12 Ancillary Equipment 3.13 Earthing and Bonding 3.14 Operational Issues 3.15 Inspection, Testing and Maintenance References and Further Reading 4. Vapour and Emission Control 4.1 Introduction 4.2 Air Quality Management 4.3 Problems Associated with Emissions 4.4 Product Characteristics and Equipment Choice 4.5 Emissions Reduction Programmes 4.6 Sources of Emissions 4.7 Emission Monitoring and Control 4.8 Vapour Lines and Ancillary Equipment 4.9 Flame and Detonation Arresters 4.10 Blowers and Eductors 4.11 Inspection, Testing and Maintenance 4.12 Emissions from Incidents and Accidents References and Further Reading 5. Jetty and Shipping 5.1 Introduction 5.2 Regulatory Considerations 5.3 Risk Assessment 5.4 Design and Construction 5.5 Jetty Infrastructure 5.6 Cargo Transfer Equipment 5.7 Waste Handling Facilities 5.8 Jetty Operations 5.9 Emergency Response 5.10 Jetty Security 5.11 Inspection, Testing and Maintenance References and Further Reading 6. Road and Rail 6.1 Introduction 6.2 Regulatory and Terminal Considerations 6.3 Road and Rail Loading Station Risk Assessments 6.4 Loading and Unloading Infrastructure 6.5 Loading Station Product Transfer Equipment and Systems 6.6 Operations 6.7 Emergency Response 6.8 Security 6.9 Inspection, Testing and Maintenance References and Further Reading 7. Warehousing and Drumming 7.1 Introduction 7.2 Regulatory Requirements 7.3 Risk Assessment and Management 7.4 Product Hazards and Classification 7.5 Dangerous Goods Packaging Requirements 7.6 Labelling of Drums and IBCs 7.7 Drumming 7.8 Warehouse and Infrastructure 7.9 Product Implications and Warehouse Types 7.10 Storage Arrangements 7.11 Training 7.12 Drum and IBC Filling 7.13 Warehousing Operations 7.14 Pallets 7.15 Fire Safety 7.16 Emergency Response 7.17 Security 7.18 Inspection, Testing and Maintenance References and Further Reading 8. Hazardous Area Classification 8.1 Introduction 8.2 Regulatory Considerations 8.3 Hazardous Area Classification Systems 8.4 Fire and Explosion 8.5 Product Characteristics 8.6 Hazardous Area Classification – Assessing the Risk 8.7 Documentation 8.8 Overview of ATEX Requirements 8.9 Vehicles as Mobile Sources of Ignition 8.10 Inspection, Testing and Maintenance References and Further Reading
VOLUME II
9. Fire Safety 9.1 Introduction 9.2 Regulatory Considerations 9.3 Classification of Fires 9.4 Terminal Fire and Explosion Hazard Areas 9.5 Fire-Related Hazards 9.6 Fire and Explosion Hazard Management (FEHM) 9.7 Fire Prevention 9.8 Fire and Flammable Vapour Detection 9.9 Fire Protection 9.10 Fire Response Strategies and Options 9.11 Inspection, Testing and Maintenance References and Further Reading 10. Buildings 10.1 Introduction 10.2 Regulatory Considerations 10.3 Building Risk Assessments 10.4 Fires 10.5 Toxic Materials 10.6 Explosions 10.7 Management of Change 10.8 Terminal Layout and Buildings 10.9 General Ventilation Issues 10.10 Emergency Response 10.11 Security 10.12 Inspection, Testing and Maintenance References and Further Reading 11. Solid and Liquid Waste 11.1 Introduction 11.2 Regulatory Compliance 11.3 Terminal Waste Inventory 11.4 Water Management 11.5 Sewers, Drains and Bunds 11.6 Water Collection and Treatment Facilities 11.7 Cleaning 11.8 Waste 11.9 Waste Handling 11.10 Carriage and Disposal of Hazardous Waste 11.11 Inspection, Testing and Maintenance References and Further Reading 12. Electrical Equipment and Power Distribution 12.1 Introduction 12.2 Regulatory Considerations 12.3 Risk Assessment 12.4 System Drawings and Schedules 12.5 Substations and Switch Rooms 12.6 Cables and Ancillary Equipment 12.7 Motors and Ancillary Equipment 12.8 Lighting 12.9 Transportable and Portable Equipment 12.10 Alternative Energy Sources 12.11 Earthing and Static Protection 12.12 Cathodic Protection 12.13 Fire Safety 12.14 Emergency Response 12.15 Security Arrangements 12.16 Inspection, Testing and Maintenance References and Further Reading 13. Traffic Circulation and Control 13.1 Introduction 13.2 Regulatory and Terminal Considerations 13.3 Traffic Circulation Risk Assessments 13.4 Vehicle Safety 13.5 General Design Principles for Roads and Facilities 13.6 General Traffic Management 13.7 Receipts and Deliveries 13.8 Driver Requirements and Control 13.9 Emergency Response 13.10 Security 13.11 Inspection, Testing and Maintenance References and Further Reading 14. Personnel Safety 14.1 Introduction 14.2 Factors Affecting Health and Safety 14.3 Occupational Health Controls 14.4 Personal Protective Equipment 14.5 Job Safety Analysis 14.6 Permit to Work Systems References and Further Reading 15. Emergency Response 15.1 Introduction 15.2 Regulatory Considerations 15.3 Assessment of Risks and Consequences 15.4 Emergency Preparedness 15.5 Emergency Response Plans (ERP) 15.6 Post Incident Cleanup and Recovery 15.7 Information and Training 15.8 Resources (Manpower/Equipment/Materials) 15.9 Security Arrangements 15.10 Inspection, Testing and Maintenance References and Further Reading 16. Security 16.1 Introduction 16.2 Regulatory Considerations 16.3 Security Risk Assessment 16.4 Security Plan 16.5 Security Performance Standards 16.6 Security Training 16.7 Site Security 16.8 Security and the Carriage of Dangerous Goods 16.9 Pipeline Security 16.10 Jetty Security 16.11 CCTV Cameras 16.12 Computer and Document Security 16.13 Security Against Insider Activities 16.14 Security and Emergency Response 16.15 Inspection, Testing and Maintenance References and Further Reading 17. Management of the Terminal 17.1 Level 1 – Policies and Procedures 17.2 Level 2 – Objectives and Management Plans 17.3 Level 3 – Operational Disciplines
Abbreviations
AAR Association of American Railroads ABS Acrylonitrile butadiene styrene AC Alternating current ACEP Approved container examination programme ADSL Asynchronous Digital Subscriber Line AFFF Aqueous film forming foam AIB Asbestos insulating board ALARP As low as reasonably practicable ANSI American National Standards Institute API American Petroleum Institute ATEX Directive regarding explosive atmospheres (from Atmosphères Explosibles) BA Breathing apparatus BLEVE Boiling liquid expanding vapour explosion BLU Code Code of Practice for the Safe Loading and Unloading of Bulk Carriers BOD Biological oxygen demand BPEO Best practical environmental option BS EN British Standards European Norm C2H2 Ethyne (acetylene) C2H4 Ethene (ethylene) C2H6 Ethane C2H8 Butylene C3H6 Propylene C3H8O3 Propane-1,2,3-triol C4H6 Buta-1,3-diene C4H10 n-Butane CAD Computer aided design CAF Compressed asbestos fibre CAS Chemical Abstracts Service CB Circuit breaker CCNR Central Commission for the Navigation of the Rhine CCTV Closed circuit television CDI Chemical Distribution Institute CDI-M CDI-Marine CDI-T CDI-Terminals CDM Construction, design and management CE Conformité Européenne (European conformity) CENELEC Comité Européen De Normalisation CFD Computational fluid dynamics CFR Code of Federal Regulations CH4 Methane CIRIA Construction Industry Research and Information Association Cl Chlorine CLP Regulation European Regulation (EC) No 1272/2008 on Classification, Labelling and Packaging of Substances and Mixtures CO Carbon monoxide CO2 Carbon dioxide COA Certificate of analysis COD Chemical oxygen demand COMAH Control of Major Accident Hazards Regulations 1999 COW Crude oil washing COWS Crude oil washing system CP Centipoise CPC Circuit protective conductor CPI Corrugated plate interceptor CS Carbon steel CSA Canadian Standards Association CSC International Convention for Safe Containers 1972 CSC Container survey certificate CT Current transformer CTU Cargo transport unit DAF Dissolved air flotation DAS Dissipation array system DC Direct current DCMA Double counterweight marine arm DCS Distributed control system DDOS Distributed denial of service DG Dangerous goods DGSA Dangerous Goods Safety Advisor DME Dimethyl ether DO Dissolved oxygen DOS Declaration of Security DOS Denial of Service DPD The Dangerous Preparations Directive (1999/45/EC) DSD The Dangerous Substances Directive (67/548/EEC) DVB Divinylbenzene DWT Deadweight EC CHIP Chemicals hazard information and packaging for supply ECC Emergency control centre EDI Electronic data interchange EEMUA Engineering Equipment and Materials Users’ Association EFRT External floating roof tank EINECS European Inventory of Existing Commercial Chemical Substances EIV Emergency isolation valve ELINCS European List of Notified Chemical Substances EMS Environmental management system EmS Guide Emergency Response Procedures for Ships Carrying Dangerous Goods EPA Environmental Protection Agency ERC Emergency release couplings ERP Emergency response plans ERS Emergency release system ESD Emergency shutdown ESFR Early suppression fast response ETBE Ethyl tert-butyl ether FBMA Fully balanced marine arm FEHM Fire and explosion hazard management FFFP Film forming fluoroprotein FIFO First in first out FMEA Failure modes and effects analysis FOSFA The Federation of Oils, Seeds and Fats Associations FP Fluoroprotein FRP Fibreglass reinforced polyester FRT Fixed roof tank FSA Facility Security Assessment FSO Facility Security Officer FSP Facility Security Plan GFCI Ground fault circuit interrupter GFP General fire precautions GHS Globally Harmonized System of Classification and Labelling of Chemicals GMA Glycidyl methacrylate GVW Gross vehicle weight H2O Water H2S Hydrogen sulphide H2SO4 Sulphuric acid HAC Hazardous area classification HAP Hazardous air pollutant HAVS Hand-arm vibration syndrome HAZAN Hazard analysis HAZID Hazard identification HAZOP Hazard and operability analysis HCl Hydrogen chloride HCN Hydrogen cyanide HDPE High density polyethylene HEA Hydroxyethyl acrylate HLCO High level cut-off HMPE High modulus polyethylene HPA Hydroxypropyl acrylate HSE Health and Safety Executive HSE Health, safety and environment IAF Induced air flotation IAPH International Association of Ports and Harbors IBC Intermediate bulk container IBC Code International Code for the Construction and Equipment of Ships Carrying Dangerous Chemicals in Bulk ICI Imperial Chemical Industries ICS International Chamber of Shipping IDLH Immediately dangerous to life and health IEC International Electrotechnical Commission IECEx International Electrotechnical Commission System for Certification to standards relating to equipment for use in explosive atmospheres IED Improvised explosive device IEEE Institute of Electrical and Electronics Engineers IES Illuminating Engineering Society of North America IFRT Internal floating roof tank IMDG International Maritime Dangerous Goods (IMDG) Code IMO International Maritime Organization IP Ingress protection IP Code Institute of Petroleum (IP) Code ISA International Society of Automation ISGINTT International Safety Guide for Inland Navigation Tank-barges and Terminals ISGOTT International Safety Guide for Oil Tankers and Terminals ISO International Organization for Standardization ISPS Code International Ship and Port Facility Security (ISPS) Code IUPAC International Union of Pure and Applied Chemistry JSA Job safety analysis kPa Kilopascal KPI Key performance indicator kW KilowattLAH Level alarm high LAHH Level alarm high-high LC50 Lethal concentration, 50% LD50 Lethal dose, 50% LED Light-emitting diode LEL Lower explosive limit LEV Local exhaust ventilation LFL Lower flammable limit LOA Length overall LOC Limiting oxygen concentration LPG Liquefied petroleum gas LSA Low specific activity LSHH Level switch high-high MAPP Major accident prevention policy MARPOL 73/78 International Convention for the Prevention of Pollution from Ships 1973 as amended by the Protocol of 1978 MAWP Maximum allowable working pressure MBL Maximum breaking limit MCA Maritime and Coastguard Agency MCB Miniature circuit breaker MCCB Moulded case circuit breaker MCERTS Monitoring Certification Scheme (set up by the UK Environment Agency) MCF Minimum continuous flow MEV Mechanical extract ventilation MIE Minimum ignition energy mJ Milli joule MLSS Mixed liquor suspended solids MoC Management of change MOC Minimum oxygen concentration MP/AR foam Multi-purpose/alcohol resistant foam MS Methylstyrene MSDS Material safety data sheet MTBE Methyl tert-butyl ether MVCS Marine vapour control system MWP Maximum working pressure N2 Nitrogen NaOH Sodium hydroxide NDT Non-destructive testing NEC National Electric Code NFPA National Fire Protection Association NH3 Anhydrous ammonia NiCd Nickel cadmium NiMH Nickel-metal hydride NO Nitrogen monoxide NO2 Nitrogen dioxide NORM Naturally occuring radioactive material NOx Nitrogen oxide NPRA National Petrochemical and Refiners Association O Ozone OCB Oil circuit breaker OCIMF Oil Companies International Marine Forum OSHA US Department of Labor, Occupational Safety and Health Administration PCB Polychlorinated biphenyls PEL Permissible exposure limit PERC Powered emergency release coupling PES Programmable electronic system PFSO Port Facility Security Officer PFSP Port Facility Security Plan PM10 Particulate matter with particles measuring 10 μm or less PMS Planned maintenance system POPs Persistent organic pollutants PPE Personal protective equipment psi Pounds per square inch PSN Proper shipping name PTFE Polytetrafluoroethylene PTW Permit to work PTZ Pan tilt zoom PVA Polyvinyl alcohol PVC Polyvinyl chloride PVRV Pressure vacuum relief valve PV valve Pressure vacuum valve QCDC Quick connect/disconnect coupling QRA Quantitative Risk Assessment Quantitative Risk Analysis
Quantified Risk Assessment Qualitative Risk Analysis RCCB Residual current circuit breaker RCD Residual current devices RCMA Rotary counterweight marine arm RCMS Responsible care management system REACH Regulation on Registration, Evaluation, Authorisation and Restriction of Chemicals RFID Radio-frequency identification RGA Retractable grounding assembly RME Rapeseed methyl ester ROPS Roll-over protection system ROSOV Remotely operated shutoff valve RPE Respiratory protective equipment RV point Rendezvous point RWP Rated working pressure SAF Submerged aerated filters SCADA Supervisory Control and Data Acquisition SCBA Self-contained breathing apparatus SD Synthetic detergent SDS Safety data sheet SELV Separated or Safety extra low voltage SG Specific gravity SIGTTO Society of International Gas Tanker and Terminal Operators SIRE Ship Inspection Report Programme SMS Safety management system SO2 Sulphur dioxide SOLAS International Convention for the Safety of Life at Sea 1974 SPZ Source protection zone SS Stainless steel SS Suspended solids STCW International Convention on Standards of Training, Certification and Watchkeeping for Seafarers STP Standard temperature and pressure STS Ship to ship SUDS Sustainable drainage systems SVP Saturated vapour pressure (or saturation vapour pressure) SWL Safe working load T-Class Temperature class T-Rating Temperature rating TAC Toxic air contaminant TAME Tertiary amyl methyl ether TBC Tertiary butyl catechol TDI Toluene diisocyanate TLV Threshold limit value TPI Tilted plate interceptor TQM Total quality management TREM Card Transport and emergency cards TSS Total suspended solids TWA Time-weighted average UEL Upper explosive limit UFL Upper flammable limit UKC Underkeel clearance UNSCETDG United Nations Sub-Committee of Experts on the Transport of Dangerous Goods UPS Uninterruptible power supply USCG United States Coast Guard VAM Vinyl acetate monomer VCE Vapour cloud explosion VCF Volume correction factors VCM Vinyl chloride monomer VLCC Very large crude carrier VMDS Vehicle mounted data system VOC Volatile organic compound VRU Vapour recovery unit WBV Whole-body
The CDI is a chemical industry organization, incorporated under the law of the Netherlands as the Stichting Chemical Distribution Institute (CDI) and operates as a non-profit making foundation.
CDI is managed by a Board of Directors consisting of seven individuals nominated by the participating chemical companies. The Board of Directors establishes policy and is responsible for overall affairs of the foundation. Individual Executive Boards are elected to oversee and direct the staff managing day to day activities for the Marine, Terminals and Marine Packed Cargo Schemes.
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