Prepared by :Subjit Dash,

Masters of technology – Safety Engineering

National Institute of Technology, Rourkela

Ammonia

CONTENTS

PURPOSE

Learning through the experience of others

Physical & Chemical Properties•AMMONIA HAZARDS•TYPES OF EXPOSURE•SYMPTOMS OF EXPOSURE

In Case of Emergency

First Aid

Personal Protective Equipment used during Ammonia Handling

In Case of Emergency

Occupational Health Hazards

Model Emergency Siren Codes

Case Study on Gas Leakage

Conclusion

PURPOSE

1. Your own personal safety• There is ammonia on our premises

• We want you to be aware of it

• We also want you to be prepared

2. Education• You should know what ammonia is

• Emergency procedures should be well known to ALL employees

3. Preparation• Be ready for the worst case

• If the worst case happens, preparation saves lives

Learning through the experience of others:1. Blast at Vatva ammonia plant kills one, India, 12 April 2010.

The accident occurred when a vessel emitting ammonia gas burst, damaging the factory premises.

2. Ludhiana: Ammonia gas leak , 15,July.2015

At least five people were killed and more than 140 injured when a gas tanker carrying liquefied ammonia got stuck under the Doraha flyover

ORIGIN OF ACCIDENT DATE LOCATION PRODUCTS INVOLVED

NUMBER OF

DEATHS INJURED EVACUATED

Leakage 17.01.1989 Bhatinda Ammonia - 500 ..

Leakage 24.06.1987 Bhopal Ammonia 200 000

leakage (transport accident) 21.01.1997 Bhopal Ammonia 400

Leakage in an Ice Factory 00.07.1990 Lucknow Ammonia gas 200

Transport accident 00.01.1991 New Bombay Ammonia gas 1 150

Transport accident 00.12.1995 Maharashtra Ammonia gas 2 000

Learning through the experience of others: contd.

PHYSICAL & CHEMICAL PROPERTIES

Ammonia is:§ Found naturally in the atmosphere

§ 80% of manufactured ammonia is used as a fertilizer

§ Used in a solution with water for cleaning of households and commercial use

§ Used in the production of several manufactured goods including dyes, plastics and other chemicals

§ Used as a refrigerant gas in cooling systems

§ Ammonia in liquid form is colorless but gives white expanding clouds when vaporized in atmosphere.

§ Ammonia readily dissolves in water.

§ Under normal atmospheric pressure & temp., Ammonia is present in gaseous form.

§ Ammonia has got a pungent smell & the presence can be felt at as low a level as 1 part permillion.

§ Ammonia is lighter than air & therefore gets dispersed easily.

§ This threshold limit value (8hrs. Safe exposure without any side effects) of ammonia is 25 parts per million by volume.

§ Fire hazard is extremely low (Flammable range of ammonia is 16 to 25 percent by volume in air).

PROPERTIES

¨ CHEMICALS :

a) Forms explosive compound by reacting with halogens hypochlorite, mercury, etc.

b) Copper, zinc, cadmium are attacked by ammonia in the presence of moisture.

¨ FIRE :Risk of serious fire & explosion prevails while working on Ammonia System when Oxy-acetylene burning or welding is performed

¨ ENGINEERING HAZARDS :

a) Failure of gaskets joints, safety interlocks.b) Corrosion of external surfaces of pipes.c) Non condensable gases – results high discharge pressure.

AMMONIA HAZARDS

TYPES OF EXPOSURE ´ SkinAnhydrous ammonia causes freezing and chemical burn wherever skin and clothing are moist. The sub-zero temperature of escaping anhydrous ammonia freezes clothing to the body. ´ Eyes Eyes are continually bathed in moisture. Anhydrous ammonia will seek this moisture. The burns will result in damage to the eyes, such as cataracts, glaucoma and possibly some permanent vision loss and disfigurement. ´ Lungs At low concentrations, the odor of anhydrous ammonia usually will drive the unprotected worker away from the scene.

Symptoms of exposure:§ Pungent, suffocating smell at low concentrations

§ Eye, nose & throat irritation

§ Burns & frostbite from contact with liquid form

§ Difficulty in breathing

§ Loss of consciousness

EXPOSURE (ppm)

EFFECT ON HUMAN BODY PERMISSIBLE EXPOSURE

25 PPM Odor detectable by most persons Max. 8 Hrs.

100 PPM 1. Eye irritation.2. Conjunctivitis.3. Swelling of eye lids.4. Lips dry.5. Red mouth/Throat burning.

Deliberate exposure for long period not permitted.

400-700 PPM Immediate eye and respiratory tractirritation.

No serious effect up to 1 hr.

1700 PPM Coughing severe eye and respiratory tract protection

Could be fatal after ½ an Hrs.

2000-3000 PPM Skin Blisters & Burn within seconds. Could be fatal after 15 Min.

5000-10000 PPM Suffocation within minutes Fatal within minutes.

EXPOSURE LEVELS AND EFFECTS OF AMMONIA ON THE HUMAN BODY

IN CASE OF EMERGENCY

Alarms:1. Should there be an ammonia release:

§ An alarm will sound…

§ A call will be made…

§ You will hear this sound…

§ When heard, emergency actions must be taken…

Evacuation:2. When the alarm sounds:

§ Stop working IMMEDIATELY……!

§ Proceed to muster point.

§ Exit quickly

§ If someone is overcome, do not go back in for them

§ Wait for instructions from the respective line manager /Safety department.

Gathering:3. While evacuation:

§ Pay attention to wind direction

§ Remember that ammonia has an affinity towards moisture.

§ Inform the direction from where the Emergency crews shall arrive.

§ Make sure you are accounted and dismissed properly.

All Clear:4. Do not return to work until:

§ All clear comes from the respective department.

§ Emergency crews give the all clear…

§ Asked to return by…

Drills:5. Procedures for emergency drills:

§ Preparation is the key to avoiding catastrophe

§ Failure to participate, will result in disciplinary action

§ Drill should be conducted periodically(time frame).

§ Results of the drills should be recorded and reviewed by the mock drill personnel.

´ Isolate the work area.

´ Use personal protective equipment.

´ Keep water hose always ready.

´ Depressurize area of work.

´ Confirm the removal of ammonia from the system by crack opening the drain / vent valves.

´ Keep drain / vent always open while working on ammonia lines.

´ In case of minor leakage while working immediately pour water on the leakage point.

´ Keep emergency vehicle ready.

´ Ensure NH3 safety trained personnel only to work.

PRECAUTIONS WHILE WORKING ON AMMONIA LINES

FIRST AID

FIRST AID FOR AMMONIA EXPOSURE.´ Flush eyes with water. Keep eyelids open while flushing.

´ Eyes can be washed with 0.5-1% alum.

´ Neutralize ammonia by mouthwash garble & with a mixture of one part of vinegar with four parts of warm water.

´ Thoroughly wash the affected skin with running water for at least 10 min.

´ Drink plenty of water at regular intervals.

´ Inhale warm water vapors.

´ In case of severe discomfort, consult a doctor.

´ Antidote ; Atropine injection 0.6 mg & repeat 2 hourly till necessary.

´ Pour sufficient water at leakage point.

´ Wear respiratory protection.

´ Isolate the area of leak.

´ Depressurize the pipe line.

´ Rectify the leakage point.

ACCIDENTAL RELEASE OF AMMONIA - ACTIONS

PERSONAL PROTECTIVE EQUIPMENT USED DURING AMMONIA HANDELLING

Ammonia Face Mask with canister

Compressed Air Breathing Apparatus

Safety Shower

Eye Washing

Essential PPE

OCCUPATIONAL HEALTH HAZARDS

An OCCUPATIONAL DISEASE is a health problem caused by exposure to a workplace health hazard. Learn about health hazards in your workplace and what to do if you think you've become ill because of something you did or were exposed to at work.

1.NOISE2.VIBRATION3.IONIZING RADIATION4.NON-IONIZING RADIATION5.OPTICAL6.EXTREME TEMPERATURE

NOISENoise is unwanted sound. Sound is a form of mechanical energy caused by the vibration of the air. When sound vibrations reach the listener they are detected by a delicate mechanism in the inner ear and perceived as sound by the brain. Sound has three principal characteristics: frequency, amplitude and time pattern.

HEALTH EFFECT:Excessive noise has the potential to impair hearing, or even destroy it. Noise may also put stress on other parts of the body causing the abnormal secretion of hormones, the tensing of muscles and other health effects. Sleeplessness and fatigue are among the symptoms.

Impaired Hearing

Stress

Sleeplessness

VIBRATIONVibration is a rapid alternating or reciprocating motion. It can affect all or part of the body. For example, driving a tractor over bumpy roads in a poorly designed seat vibrates the entire body. Prolonged use of a vibrating hand tool can affect the hands and arms.

HEALTH EFFECT:The energy from vibration is absorbed by the tissues and organs of the body. Whole body vibration can lead to lower back pain. Hand-arm vibration causes damage to blood vessels, impairing circulation in the hand. This leads to a condition known as white finger, or Reynaud's phenomenon.

Back Pain

White Fingers

Ruptured Blood Vessels

IONIZING RADIATION Ionizing radiation is produced by the natural decay of radioactive elements such as uranium. It has enough power to strip electrons from atoms and cause ionization. This can interfere with the body's cellular structure and cause genetic damage.

HEALTH EFFECT:The greatest effects of ionizing radiation are on cells that are rapidly dividing. The blood forming system in the bone marrow is easily damaged. Ionizing radiation has the potential to cause cancer in many body organs. Cancer may appear after a latency period of as little as 2 to 4 years in the case of leukemia, and 5 to 30 years in the case of most other cancers. Ionizing radiation can damage the genetic material in the sperm or the egg cells, causing mutations. These mutations can be passed on to offspring.

Cancer Cells

Aging

Radiation Burn

NON- IONIZING RADIATIONNoise is unwanted sound. Sound is a form of mechanical energy caused by the vibration of the air. When sound vibrations reach the listener they are detected by a delicate mechanism in the inner ear and perceived as sound by the brain. Sound has three principal characteristics: frequency, amplitude and time pattern.

HEALTH EFFECT:Ultraviolet Radiation Ultraviolet (UV) radiation can burn the skin as in sunburn. Long-term exposure can lead to aging of the skin & may cause skin cancer. Infrared Radiation Infrared radiation is experienced primarily as radiated heat. Heating and warming equipment can cause an overexposure, leading to skin burns and eye damage. Shielding and enclosures may be required along with proper eye protection. Microwave and High Radio Frequency Radiation Microwave and high radio frequency radiation is found in radar, communications and cooking operations. Microwaves interact with the body by raising the temperature of body organs. It is suspected that the brain, the eyes and the reproductive organs are vulnerable. Low Frequency Radiation The longer wavelengths including power line transmission frequencies, broadcast radio, and short-wave radio can produce a general heating of the body. The potential hazards are greatest for those working close to powerful radio transmitters.

Sun Burn

Human Cell Damage

Eyes Damage

OPTICALEye disorders resulting from work are largely under-reported and they can be easily prevented. The most common types of eye injuries result from small foreign objects ejected by tools or during activities such as grinding, welding and hammering. In the diagnosis and treatment of eye disorders, it is important to bear in mind the nature of the patient’s occupation and the nature of work activity at time of injury.

HEALTH EFFECT:The common eye disorders in the occupational setting are foreign bodies in the eye and chemical irritation. Foreign bodies may cause little or no damage if confined to the conjunctiva, although subsequent rubbing of the eye may cause severe conjunctival laceration or corneal abrasions.

conjunctival laceration

corneal abrasions

EXTREME TEMPERATUREDiseases caused by excessive heat (heat disorders) can result from prolonged exposure to excessive heat causing the body’s cooling mechanism to break down, especially in un-acclimatized workers. A rise in the core body temperature may lead to temporary or permanent disturbances in bodily functions which may be further aggravated by strenuous physical activity.

HEALTH EFFECT:Heat disorders can be viewed as a continuum of illnesses ranging from mild presentation as heat rash, syncope and heat cramps to the more severe presentation of heat exhaustion and heat stroke

Heat Cramps

Heat-Rash

Syncope

MODEL EMERGENCY SIREN CODES

• 3 Minutes ON

• 20 Secs ON, 5 Secs OFF, 8 Cycles

• 20 Secs ON, 5 Secs OFF, 5 Cycles

• 10 Secs ON, 5 Secs OFF, 3 Cycles

Leakage On- Site Emergency

All ClearOff – Site

Emergency / Disaster

MODEL EMERGENCY SIREN CODES

CASE STUDY ON GAS LEAKAGE

´ Bhopal Gas Tragedy

´ Chlorine leak on Mumbai Port Trust's Sewri yard

´ The Chlorine Gas Leak at Jamshedpur on 27th May,2008

CASE STUDY ON GAS LEAKAGE

CONCLUSION

Conclusion:1.) The potential for exposure to ammonia is isolated

2.) Preparation is key in the case of an accidental exposure

3.) Ammonia must be taken seriously and considered dangerous

4.) Ammonia will seek out water in the atmosphere

5.) Preparation is the difference between an accident and a disaster