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ISOPA Driver Training ProgramRevision 20151
Driver Product & Safety Training
MDI / TDI Bulk Liquid Transportation
ISOPA Driver Training ProgramRevision 2015
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ISOPA Driver Training ProgramRevision 20152
Driver Training MDI / TDI
Company [name]
Location [place]
Date 19/04/23
Trainer [name]
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ISOPA Driver Training ProgramRevision 20153
Background
MDI / TDI can be handled safely and are in widespread use across the world.
This programme helps in the safe transport of these chemicals by ensuring proper training of drivers
The training package is a joint effort of ISOPA and the carriers based on practical experience.
Drivers who successfully complete the driver training are issued with a MDI / TDI Driver Training Card
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ISOPA Driver Training ProgramRevision 20154
Introduction ISOPA
European
ISOcyanate Producers Association
See website www.isopa.org
Member companies:
olyo
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ISOPA Driver Training ProgramRevision 20155
ISOPA Member Companies
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ISOPA Driver Training ProgramRevision 20156
Applications
Polyurethanes are used in many products and articles:
Car seats, Steering wheels Sports shoes Sofas, Chairs and Mattresses Fibre board (MDF) Expansion joints & Gasket seals Insulation foam (refrigerators, tanks, buildings) Coatings, Paints ...and many more
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ISOPA Driver Training ProgramRevision 20157
Appearance
Liquid Reacted
MDI
Clear to brownSlightly musty
BrownCrusty
TDI Clear to pale yellowSharp, pungent
WhiteFoamy
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ISOPA Driver Training ProgramRevision 20158
MACMaximum Allowable Concentration
MAC : 5.0 – 10.0 ppb
Odour threshold : 0.2 – 0.4 ppm
Therefore: When you smell it, it’s above the limit ! No used PPE in the cabin
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ISOPA Driver Training ProgramRevision 20159
Main Physical and Chemical Properties (1)
Vapour pressure:
Dangers of MDI and TDI are of the same magnitude but… vapour pressure of TDI is much higher (20x), therefore the RISKS of TDI are much bigger
Vapour density = 6× Air density
i.e. the vapours are heavier than air!
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ISOPA Driver Training ProgramRevision 201510
Main Physical and Chemical Properties (2)
Density range 1.20 – 1.29(For TDI filling degree conform ADR see next slide)
Important temperatures (TDI):• Crystallization starts at ± 15°C (product temp.)• Melting when reheated to ± 45°C (product temp.)
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ISOPA Driver Training ProgramRevision 201511
TDI / MDI*
20%
80%
±95%
OK
NOT OK
OK
NOT OK
ADR 4.3.2.2 Degree of
filling
4.3.2.2.4
“Where shells are not
divided by partitions or
surge plates into sections
of not more than 7,500
litres capacity, they shall
be filled to not less than
80% or not more than
20% of their capacity”.
Degree of Filling for TDI
*) For MDI there is no legal requirement but most producers follow the same rules as for TDI
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ISOPA Driver Training ProgramRevision 201512
Main Physical and Chemical Properties (3)
MDI / TDI reacts with water (including air!)
Temperature and pressure (CO2 release) goes up significantly in transit without external heating
Possible water sources can be:• Tank cleaning operations• Opening manlids
– for: sampling, discharge etc.– by: customs, customers, drivers etc.
• Non-dried air from customer’s installation• Silica gel filter malfunction
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ISOPA Driver Training ProgramRevision 201513
Effect of MDI/TDI on your Health
Short term / one-off exposure above safe level
- Irritates mouth, throat, lungs
- Tight chest, coughing
- Difficulty in breathing
- Eyes watering
- Itching, red skin (immediately or delayed)
- May be hot or burn
Symptoms can occur up to 24hrs after exposure
Do not try tohide problems !
Seek medical assistance
immediately !
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ISOPA Driver Training ProgramRevision 201514
Long term/repeated over- exposure from breathing or skin contact leads to risk of sensitisation
Symptoms such as occasional breathing difficulties similar to asthma, hay fever, sneezing
When sensitised, potentially severe asthma in the case of even low MDI/TDI exposure
Sensitisation could prevent working with diisocyanates for life; early and prompt removal from exposure can typically result in cessation of allergic responses
Sensitisation is non-reversible and is a reaction of theimmune system. Not to be confused with irritation
Effect of MDI/TDI on your Health
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ISOPA Driver Training ProgramRevision 201515
Product Hazards: TDI
Very toxic by inhalation
Irritating to eyes, respiratory system and skin
Risk of sensitisation by inhalation and skin contact
Warning: This effect can be delayed for as long as
24 hours after exposure!
Sensitisation means build up of irreversible allergic reactions
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ISOPA Driver Training ProgramRevision 201516
Product Hazards: MDI
Harmful by inhalation
Irritating to eyes, respiratory system and skin
Risk of sensitisation by inhalation and skin contact
Warning: This effect can be delayed for as long as
24 hours after exposure!
Sensitisation means build up of irreversible allergic reactions
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ISOPA Driver Training ProgramRevision 201517
Product Transport Use
MDI Not regulated but still harmful
TDI ADR / RID / IMDGUN 2078Class 6.1Packing Group IIMarking and Labelling:ADR tunnel category: (D/E)
Classification and Placarding
602078
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ISOPA Driver Training ProgramRevision 201518
PPE – MDIPersonal Protective Equipment
Hard hat Goggles Liquid-tight gloves Safety shoes / boots Overall Eyewash bottle
As a minimum...
• Butyl rubber• Neoprene• Nitrile rubber
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ISOPA Driver Training ProgramRevision 201519
PPE – TDIPersonal Protective Equipment
Hard hat Full face mask (with appropriate
filter) Liquid-tight gloves Safety shoes / boots Full chemical suit Eyewash bottle
As a minimum...
• Butyl rubber• Neoprene• Nitrile rubber
Filter to be replaced after 2 days unless different guidance from
supplier
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ISOPA Driver Training ProgramRevision 201520
Health Effects - Contact Lenses
When eye contamination you will not be able to remove the lenses as they will stick to the eye surface due to reaction between the lenses and the eye and water layer between them.
You should not use
contact lenses when
handling isocyanates
You should not use
contact lenses when
handling isocyanates
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ISOPA Driver Training ProgramRevision 201521
Personal Health (1)
Use an appropriate cartridge / canister (min. AP2)
Filter to be replaced after 2 days unless different guidance from supplier
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ISOPA Driver Training ProgramRevision 201522
Personal Health (2)
Wash hands (& face) before eating, drinking, smoking or going to the toilet
Keep contaminated PPE out of the cabin
• A quantity of vapor equal to the size of a one Eurocent coin is enough to increase the concentration in the average cabin well above the MAC value
• Imagine working / sleeping in this atmosphere for 8 hours !
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ISOPA Driver Training ProgramRevision 201523
Product Quality Control
Certificate of Analysis (CoA)
Samples (Not recommended) • CoA is strongly preferred to a sample• Drivers should not take samples !• Never take a sample in your cab !!!
Not even for 1 minute !!!
Temperature (Customer specific)
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ISOPA Driver Training ProgramRevision 201524
Site Safety
Make yourself familiar with the site emergency policy and location of following items:
Signs & Alarms Wind direction indicator Emergency stop button Emergency shower Assembly point Waste bin (for used gaskets, gloves, etc.) Decontamination & Absorption material
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ISOPA Driver Training ProgramRevision 201525
Spill Handling (by Emergency Services)
Always wear PPE !!
Drivers should observe from a safe distance and remain available to provide information
Emergency services should:
1. Cover sewer system2. Absorb the spill3. Neutralise4. Wait (30–60 minutes after reaction has finished)5. Remove spill after reaction has finished.6. Put residues in designated chemicals waste bin7. Apply decontamination fluid
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ISOPA Driver Training ProgramRevision 201526
Loading: Key Items
PPE must be worn
Tank equipment
3-Minutes check before & after loading
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ISOPA Driver Training ProgramRevision 201527
Prevent Falling from HeightsFall protection (1)
• During unloading of TDI / MDI, you will have to work on top of your road tanker or tank container
• A US study shows that 1 in 5 driver injuries related to falling from heights and 1 in 1,000 of these injuries results in a fatality
• For TDI / MDI, a single collapsible handrail is not considered as adequate fall protection and is considered as hazardous
• The best solution is a fixed gantry or cage (top) with 360° guard rails while a mobile platform provides a cheaper and more flexible alternative (bottom)
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ISOPA Driver Training ProgramRevision 201528
If a gantry or cage is not available, the use of a fallarrest harness is an acceptable alternative.
Ensure that:•You always have your inspected and well maintained harness with you• You inspect it for defects and damage before each use• You are trained on how to wear your harness•The site provides a connection point (preferably sliding or mobile) and a lanyard (preferably with a self-lowering fall arrest line)•The site operator confirms that the site you are visiting has a rescue plan in place that will ensure a fast recovery in order to avoid suspension trauma and is present during operation.
Prevent Falling from HeightsFall protection (2)
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ISOPA Driver Training ProgramRevision 201529
Tank Equipment
Manlid must be kept closed! (moisture prevention)
Ensure customs letter (if applicable) is present
Do not mix-up the vapour return and liquid line !!!
Tank depressurised?
Cleaned tanks must be dry ! Capacity (keep filling degree in mind!)
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ISOPA Driver Training ProgramRevision 201530
3-Minutes Check before Loading
Equipment
Tanker exterior clean? Spillage tray clean? Tanker correctly labelled and placarded? All valves closed, blind flanges/caps in place? Manlid closed and bolts tightened? Check temperature
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ISOPA Driver Training ProgramRevision 201531
3-Minutes Check after Loading
Equipment
– Disconnected?
– Free of spillages including spillage tray?
– Safety handrail down?
– Valves closed, blind-flanged and new gasket?
– Only slight overpressure (max 0.1 bar)?
– Temperature setting correct?
– Sample (if necessary)?
Documentation– Transport document, Customs letter, CoA, Weight ticket,
DGD?
– Instructions in writing?
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ISOPA Driver Training ProgramRevision 201532
Transport
Hours / Speed
Check temperature (and pressure)
Reporting unsafe conditions / incidents
Parking
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ISOPA Driver Training ProgramRevision 201533
Opening of Tanks in Transit by Customs Officials
Tanks should not be opened whilst in transit because of the dangers to human health
ISOPA issued a letter to Customs Officials explaining thereasons why
Letter is available in 14 languages i.e. CZ - DE - EN - ES - FR - HU - IT - LV - PL - RO - RU - SK - TUR - UA
Letter can be downloaded from the ISOPA website http://isopa.org/product-stewardship/logistics/letter-to-customs-officers/
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ISOPA Driver Training ProgramRevision 201534
Security en Route
What to do & not to do:
Do not leave the vehicle unlocked
Do not disclose information about product carried, customer, route or destination
Park preferably on secure parking areas
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ISOPA Driver Training ProgramRevision 201535
Heating
All methods:
– Maximum product contact temperature = 60°C
– Do-not-open-the-manlid
Steam:
– Only external steam coils
– Maximum 1.7 bar (= ~ 115 °C)
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ISOPA Driver Training ProgramRevision 201536
Unloading: Key Points (1)
Follow site regulations
Behavior You are the supplier’s representative
Know the operational responsibilities betweenoperator and driver as described in the CEFIC / ECTA / FECC Best Practice for safe (un)loading of Road Freight Vehicles Behavior Based Safety Guidelines
Report unsafe conditions at customers (including near misses)
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ISOPA Driver Training ProgramRevision 201537
Storage tank capacity
• communication driver / operator
PPE must be worn
Observe connections, pressure during unloading
Samples(Report back if you have to take a sample)
Unloading methods(Details on next slides)
Unloading: Key Points (2)
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ISOPA Driver Training ProgramRevision 201538
Discharge Methods (1)Customer liquid pump and vapor return
(with hoses provided
by customer, if possible)
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ISOPA Driver Training ProgramRevision 201539
Discharge Methods (2)Customer nitrogen or dry air
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ISOPA Driver Training ProgramRevision 201540
Discharge Methods (3a)Vehicle compressor with silica gel
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Discharge Methods (3b)Vehicle compressor without silica gel
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ISOPA Driver Training ProgramRevision 201542
Spillage Tray Lay-out (example)
Liquid line and vapour return line should be properly identified
Vapour
Liquid
Pressure
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ISOPA Driver Training ProgramRevision 201543
3-Minutes Check after Discharge (1)
Equipment Disconnected? Free of spillages including spillage tray? Safety handrail down? Valves closed and blind-flanged, manlids closed? Spillage tray covers closed? Only slight overpressure (max 0.1 bar)? Depressurise at the customer if possible, or inform planner
Documentation (1) Handed to the customer? Transport documentation signed?
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ISOPA Driver Training ProgramRevision 201544
3-Minutes Check after Discharge (2)
Documentation (2)
Customer needs:• Copy of transport document signed by driver & customer• Certificate of Analysis
Driver keeps:• Copy of transport document signed by driver & customer
For TDI: Obtain or make transport document reading:
Empty tank container*), last load: UN 2078 Toluene
Diisocyanate, 6.1, II (D/E)
*) or: tank vehicle; demountable tank; portable tank
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ISOPA Driver Training ProgramRevision 201545
Near Misses & Unsafe Conditions
Iceberg Theory
Near misses & Unsafe conditions
Incidents
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ISOPA Driver Training ProgramRevision 201546
Near misses & unsafe conditions Reporting examples
Active near miss reporting will reduce / avoid serious incidents:
Road traffic incidents Equipment failures Incorrect human behavior Overflows Overpressure Spills Unexpected temperature rise (check regularly!)Unsafe working conditions (missing safety shower, unsafe access to top bulk equipment etc.) Unsecure routing
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ISOPA Driver Training ProgramRevision 201547
Incidents
So THIS is your Challenge:
You are the most important safety factor
Statistics indicate:
More than 80% of all incidents are related to human behavior
Most incidents and accidents occur during loading & unloading
(OR you will be the most important risk factor !)
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ISOPA Driver Training ProgramRevision 201548
Emergency ResponseKnow First Aid for MDI /TDI
Force open the eyelids Flush with lots of water for at least 15 minutes If in doubt, keep flushing See eye specialist as soon as possible
Immediately remove contaminated clothing Immediately wash, wash, wash with soap & water
Go outside into fresh air Doctor must be called or patient taken to
medical facility Inform supplier – who can provide
supporting information
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ISOPA Driver Training ProgramRevision 201549
Emergency ProceduresExposure to MDI / TDI
A single high exposure to MDI / TDI is one possible cause of
sensitisation
Early treatment is important
Remember that symptoms may occur later
Help is available for the doctor from ISOPA
member companies Speed is essential Practice First Aid procedures Seek medical advice
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ISOPA Driver Training ProgramRevision 201550
And ......
In any case of emergency:
call us ....
don‘t try to be a hero.....!!
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ISOPA Driver Training ProgramRevision 201551
Emergency Response
TDI Danish incident French incidents Portuguese incident Swedish incident Turkish incidentsHungarian incident
MDI British incident German incident Italian incident
– Packed– Bulk– Bulk– Bulk– Bulk- Bulk
– Bulk– Bulk– Bulk
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ISOPA Driver Training ProgramRevision 201552
Emergency Response
Emergency incident scenario
– What went well ?
– What can be improved ?
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ISOPA Driver Training ProgramRevision 201553
Test
20 multiple choice questions:
One correct answer only
Ticking more than one answer for the same question = miss
Corrections are allowed(as long as it is clear which answer you decided upon!)
The minimum score is 70% =14 correct answers
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ISOPA Driver Training ProgramRevision 201554
The End
Congratulations!
Certificates will be forwarded as soon as possible
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ISOPA Driver Training ProgramRevision 201555
While ISOPA and its members make every effort to present accurate and reliable information in utmost good faith on the basis of the best information currently available, it is to be relied upon at the user’s own risk. No representations or warranties are made with regard to its completeness, accuracy or reliability and no liability will be accepted by ISOPA nor any company participating in ISOPA for damages of any nature whatsoever resulting from the use of or reliance on the information.
Disclaimer