INTERNAL TEST

SAFETY IN CHEMICAL INDUSTRY

Duration : 90 minutes JANUARY 2005 Marks : 100

Topics : 103.1 Introduction, 103.2 Safety in Storage

Instructions : Attempt all questions enjoying internal options.

Mathematical and/or logical memory stored aid are not allowed.

1. Answer as asked for.

a. Fill in the blanks with the appropriate word.

5

i. The materials ignites in the presence of air are known as PYROPHERIC

ii. The meaning of W,X,Y,Z of HAZCHEM is CONTAIN
iii. There are 09 classes of UN classification of chemicals for transportation by road.
iv. MAGNETIC type of level indicator is used for Chlorine storage.
v. MOUNDED tanks means the tanks are above ground and covered with earth.

b. Write TRUE of FALSE for the following statements.

5

i. The difference between UEL and LEL is known as explosive range. TRUE
ii Ammonia is flammable material.FALSE
iii Chlorine is explosive material.FALSE
iv Ethylene oxide has the flammable range 3 to 100%.TRUE
v. Hazard class label expresses the material hazard by class number and picture. TRUE

c. Join the items of “A” with that of “B” appropriately.

5

A B
i Egg-cup a. Ammonia (i )
ii Sphere b. Distribution of pressure
intensity (ii )
iii Bullet c. L/D ratios is greater (iii)
iv Canned tank d. double walled corrugated
surface tank (iv )
v Ethylene oxide e. submersible pump (vi)
vi Oleum f. polymerizes with rust (v)
vi LPG g. anaesthetic at high concentration ( vi)
viii Chlorine h. corrosive (ix)
ix Caustic soda i. Non-corrosive when dry (viii)
x IDLH j. base of LOC (x)
 d. Select the right most correct answer.
5

i. Hazardous waste ID No is…

a. UN Number
b. CAS Number
c. Category from the Hazardous Waste (Management & Handling) Rules

ii EAC…
a. is also known as HAZCHEM
b. given by UN
c. applicable for road transportation of hazardous chemicals
d. all of the above
e. none of the above

iii Flash point …

a. has pressure units
b. expresses explosivity
c. is higher than higher flammability hazard
d. all of the above
e. none of the above

iv TLV…
a. is airborne concentration
b. believed safe
c. it is maximum concentration
d. all of the above
e. none of the above

v Adiabatic decomposition temperature …

a. has relation with corrosion
b. has relation with incompatibility
c. is the base for dyke segregation
d. is the base for MOC selection
e. all of the above
f. none of the above

e Underline the odd.

5

i.open cup, closed cup, sufficient vapour, spark, flash, flame sustains
ii tonner, fusible plug, valve hood, yoke clamp, tonner kit, sphere
iii float type, dial type, magnetic level indicator, barometer
iv OSHA, ACGIH, NIOSH, NIOH, OHSAS, NFPA
v.SHC, CFC, PEL, IDLH, TLV, STEL, LEL
 f Expand the terms.
5

ACGIH: American Conference of Governmental Industrial Hygienists

NIOSH: National Institute of Occupational Safety and Health
OHSAS: Occupational Health And Safety Assessment Series.
NFPA; National Fire Protection Association.
DGFASLI : Director General Of Factories Advice services and Labour Institute

Answer in detail (any ten)

40

I. Discuss about MSDS format.

MSDS format include following head/sections.It gives the detail property and characteristics of that
material/chemical.
1)Chemical Identity 2) Chemical /Physical Property 3)Fire & Explosion data 4) Reactivity
data 5)Health hazard data
6)Preventive measures 7)Emergency /First Aid 8)Additional Information 9) Manufacturing
/supplier data 10)disclaimer

II. What is the utility of physical data from the MSDS.

Physical Data /section comprises of following details
Boiling point, Melting point, Vapor density, Specific gravity, Physical state, Solubility in water, pH,
Appearance and odour.
Above data are very important for handling of material ,dyke design,storage and vessel design ,fire fighting
measures, PPEs.
If boiling point of liquid is very low ( negative ) than that material will be in form of gas at normal
atmosphere temperature / pressure so it should be kept in compressed / pressure system .
If the vapor density is higher than 1.0 ,it means higher than Air .It will remain at ground level and which is
dangerous for working nearby area in case leakage ( cloud not easily dispersed to atmosphere ) from safety
point of view like fire / health hazards etc. so in that case proper gas detection system with appropriate
location to be provided, effective ventilation should be ensured and also adequate PPEs should be available
like scba , Online BA set, mask etc. EX : cl2 having vapor density : 2.71
If specific gravity lower than material will remain on surface of water and so incase of fire it will spread
more by direct applying water so foam system should be available for effectively extinguish fire.
PH data is also important based on PH value can be decided whether acidic / alkali and accordingly measure
can be taken in caase of spill / leakage etc. ( neutralizing media can be decided )

Explain the utility of flammability data with examples.

Following data are there in this head.

1)LEL2)UEL3)Flammability /combustible liquid.4) Flash Point 5)Auto ignition temperature
6)Pyrophoric /Explosive data.
Fire range between LEL and UEL means in between concentration of LEL and UEL suitable mixture
which can be ignited and cause fire.So based on this data fire prevention can be decided Like EO having
LEL 3% and UEL 100% means between 3% and 100% concentration EO will ignite and cause fire.
Flash point means minimum temp at which sufficient vapor is generated to cause flash fire. If Material
having low flash point ( below normal atmosphere temperature than chances of fire is higher because at
any time sufficient ignitible mixture will available only it require spark for fire. So for this type of
material well advance and effective fire fighting system with detection system should be available Ex :
benzene having flash point : -11.1 Deg C
Auto ignition temp data is also important for handling and processing etc. Lower value is dangerous from
fire point of view
Some material gives hazardous / toxic fumes during fire / burning like if cl2 burn with combustible
material it gives toxic fumes.

Enlist toxicity data available in MSDS. Explain with example.

It gives route of entry : skin / eyes / inhalation / ingestion with following data :

LD50:Dosage qty due to which 50% of rat fatal by ingestion /kg of rat.
TLV : Average concentration in air at which person can work 8hrs/shift or 48 hrs/week.
STEL Short term exposure limit, average concentration in air at which person can ok for 15 mins for 4
times with 1 hr interval.
Odour Threshold.
Chemical: cl2 EO NH3 LPG
TLV 1 1 25 1000
STEL 3 35
LD50 72 350
Odour Threshold 3.5 50 46.8 5000 to 20000

III. What do you mean by reactivity ? How it is decided? Discuss NFPA signals
for reactivity.
TO BE ANSWERED.

IV. Explain UN classification of chemicals.

1. Explosive
2. Gas
2.1 Compressed non flammable
2.2 Flammable
2.3 Toxic /poisionous gas
3. Inflammable liquid
4. Solids
4.1 Combustible solids
4.2 Spontaneous combustible.
4.3 Flammable when contact with water.
5. Oxidizing Substances
5.1 Oxidizer
5.2 Organic Peroxide.
 6. Toxic /poisionous substances.
7. Radioactive
8.Corrosive.
9. Not classified.

V. Explain Emergency Action Code.

It is also know as HAZCHEM code.
It is having 2 to 3 digits .First digit will be always numeric and second and third will be alphabet
First digit
1: jet (application of water with jet.0
2: Fog(application of water with spray)
3: Foam
4: Dry agent(sand or powder)
For second & third digit
P V Full Dilute
R
S V BA Set
S BA set when fire only
T BA Set
T BA set when fire only
W V Full Contain
X
Y V BA Set
Y BA set when fire only
Z BA Set
Z BA set when fire only

VI. What are the different storage conditions for Ammonia ?

Ammonia
1. under pressure(sphere)
2. under atmospheric condition or cryogenic temp.(cone type)
3. at ambient temp/ low cap.
Spher
e Cryogenic tk
Bullet

Storage at ambient temperature and equivalent pressure is cylindrical vessels. This storage is used
when relatively small quantity are involved as practical manufacturing and transport considerations
limit the size of vessel.
Storage under pressure is sphere. Sphere can be constructed on site to hold several thousand tones
of ammonia. However very large sphere are uncommon and most vessel are in the range of 500 to
6000 tons. Refrigeration equipment may be used to lower the temperature of ammonia and in such
cases the vessels operate at lower temperature than ambient temperature vessels, this types of storage
is often said as semi pressure or semi refrigerated.
Storage at atmospheric pressure. Ammonia may be stored at atmospheric by reducing the
temperature to -33 DEG C. In this condition it may be contained in cylindrical flat bottom tanks, since
the pressure of the tank must withstand head of liquid. In practice a slight positive pressure is
maintained to simply the operation of refrigeration system. This method of storage is generally
considered economical when quantities in excess of 5000 – 6000 tons are involved.

VII. What are different types of containers used for LPG ?

Sphere : sphere is used for storing LPG in pressurized condition in case of high capacity and also it is
situated above ground ( pressure distribution taken place )

Bullet : Bullet is used for storing LPG in pressurized condition for lower capacity

Cryogenic Tank : Also used for LPG storing at atmospheric pressure by refrigeration system.
Generally it is used for storing in bulk and also when pressurized storage not allow / desirable like in
ship LPG can be stored / transferred in cryogenic only for minimizing load due to pressurized
condition.
 Mounded vessels : A storage vessel which may be sited above ground or partially buried and which is
completely covered by a mound of earth or similar inert material
Underground and mounded vessels should be placed on a firm foundation and installed so
as to prevent movement or flotation. The surface of vessel should be suitably prepared and treated to
protect them from corrosion

VIII. Sketch chlorine toner connections with a reactor.

reactor
Vaporiser
Tonner

IX. What are the safety considerations for bulk storage of Ethylene oxide ?

Sot blasting ,Inert atmosphere,Only curb.RCC Explosion barrier of 30cm thickness.

Under refrigeration condition
 X. Explain instrumentation system with block diagram.

Physical Sensor Transducer Manipulator Processor Controller Actuator Physical

system system

Indicator ,recorder

2. Attempt any ten in brief.

20

I. Sketch Ammonia spheres.

Spher Sphere Egg type

e Cladded
Leg
suppo
rt

II. Draw a neat sketch for fully mounded tank.

A storage vessel which may be sited above ground or partially buried and which is completely covered
by mound
of earth or similar inert material.
 III. Enlist various types of chlorine evaporators ?
Vertical tube bundle
Coil tube immersed in a heating bath
Concentric tube units
Kettle type evaporator ( all sketches to be draw )

IV. Comment on the term “tonner”.

Tonner is a container having capacity of 1 mt and having both ends cylindrical concave shape.
TONNER = TON + CONTAINER

V. Enlist health data of Chlorine.

TLV; 1.0ppm
STEL: 3.0 ppm
LD50: NA
Eye irritation, sneezing, copious salivation, general excitement, restlessness
High concentration causes respiratory distress and violent coughing, often with retching. Death may result
from suffocation.
Inhalation :Remove the victim to fresh air area , support respiration, give oxygen, if necesary. eyes : flush
with large amounts
of water for at least 15 mins. Seek medical aid immediately
VI. Enlist flammability data of LPG.
Flammability : Yes TDG Flammability : 02 LEL : 1.9 %
UEL : 9.5% Flash Point : Not Available Auto ignition
Temp : 466.1 propane, 405 butane Combustible Liquid : Yes Flammable
material : Yes Pyrophoric Material : No Corrosive Material : No

VII. Enlist reactivity data of Ethylene oxide.

Chemicals Stability : Stable Incompetible with other material : Bases, alcohols, m - nitro aniline,
trimethlamine, copper, iron chlorides, iron oxides and alkenethiols, perchlorate, aire, mercaptans,
magnesium Reactivity : Violent polymerization occurs on contact with ammonia, rust, alkali
hydroxides, amines, potassium, acids, covalent halides. Explosive reaction with Glycerol at 200 Degc
Hazardous Reaction Products : Not Available

VIII. Enlist physical properties of Oleum.

MSDS NOT AVAILABLE

IX. Comment of Disclaimer of MSDS.

It contains declaration for data reliability like Information contained in this material data sheet is believed
to be reliable but no representation, guarantee or warranties of any kind are made as to its accuracy,
suitability for a particular application or results to be obtained from them. It is up to manufacturer, seller
to ensure that the information , obtained in the material safety data sheet is relevant to the product
manufacture / handled or sold by him as the case may be

X. How Indian text format differs from the European text format of MSDS ?
TO BE ANSWERED.
 XI. Enlist the data available under the Chemical identity.
Chemical Name : Ammonia
Synonyms : Liquid ammonia, ammonia gas, Ammonia anhydrous Formula : NH3
U N no : 1005 Hazardous Waste ID no : 17 Chemical classification : Inorganic compound
XII. Draw a typical block diagram of chemical factory.
TO BE ANSWERE WITH DRAWING
XIII. Enlist feature of chemical industry to become inevitable.
TO BE ANSWERED

4. Answer in one sentence or phrase. (any ten)

10

I. Ammonia is non-explosive but explosive range has been described for it. Do you agree?
YES
II. What is compatibility?
TO BE ANSEWRED
III. What is characteristic of the second digit of EAC ?
Second digit will be always alphabet.It indicated for rection will be violent or not and whether to contain
or dilute and PPEs to be used .
IV. Expand ADR.
ADR: The European Agreement for transportation of Dangerous goods by Road
V. What is the unit of Burning Rate ?
mm/minute
VI. Underline the odd : Vapour density, specific gravity, evaporation rate, boiling point
VII. How toxic substance differs from poison ?
Toxic: Inhalation affects lungs.
Poisonous: Ingestion affect kidney.

VIII. Lethal dose is air borne concentration. Do you agree?

YES
IX. Explain the meaning of 3YE.
3: Use foam
Y: Violent, Use BA set when fire only and contain leak.
X. Define flash point.
Minimum temp at which sufficient vapor will be generated to give flash fire.
XI. Define TLV.
Threshold Limit value : Avg. concentration in which person can work without any adverse effect for 08
hrs in working day or 40 hrs in a week
How PEL differs from TLV.
PEL will be always lower or equal to TLV
XII. What do you mean by DISH in industrial safety field at Gujarat ?
` DISH: Directorate of Industrial Safety and Health.
---- x ----