final version lr 29 dec 2011

Side view of GPIC Urea bulk storage

President’s MessageIn GPIC, we are committed to upholding our mission and endeavour to use only the best practices in all our manufacturing systems and operating procedures. We continuously strive to maintain GPIC as a safe, healthy and environmentally friendly facility as part of our sustainability process. Our commitment is a testimony of our products being of the highest quality and being to the complete satisfaction of our worldwide end users.

The product handling and export facility is the main chain link between the process and export activities that maintains our product quality at topmost standards. The state-of-the-art Urea export facility is a highly mechanized operation that requires vigilance and strict adherence to safety, health and environmental regulations. This eliminates the risk of injury, pollution to the environment and ensures the delivery of best product quality throughout the supply chain process, down to the end user.

This booklet is the second issue, endorsing our continued improvement practices and reflects our commitment as an accredited Responsible Care (RC 14001) and socially responsible organization. The booklet outlines the objective of increasing awareness of all personnel involved in this field in handling and transporting granular Urea including customers. It also highlights the importance of safety, security and hygiene and other key characteristics and aspects related to this product namely, storage, transfer and export operations.

Abdulrahman JawaheryPresident

The guidelines illustrated in this book are a summary of practices that are proven to be appropriate and suitable for handling, transport, and storage of granular Urea and GPIC shall not be liable for errors, omissions, or incorrect use of these guidelines. The mentioned data are based on the current state of knowledge and insights, and cannot be considered as guaranteed.

GPIC Urea export jetty

Contents

1. Introduction

2. Material Safety Data Sheet (MSDS) of Urea

3. Product Handling

3.1 Shipping

3.2 Trucking from Docks to Warehouse

3.3 Warehouse

3.4 Transport and Handling of Urea Bags

4. GPIC Marine Terminal Rules And Requirements

4.1 Security

4.1.1 Rules and Procedure

4.1.2 Ship-Shore Pre-Loading Meeting

4.1.3 Access to Marine Terminal And Jetty

4.1.4 Precautions for Vehicle Entry

4.2 Hygiene and AqIS Compliance

4.2.1 AqIS Guidelines for GPIC Marine Terminal

4.2.2 AqIS Regulations and Guidelines for Ships

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GPIC Urea product produced according to the highest international quality standards

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1- IntroductionUrea is a hygroscopic material; its quality can be affected during ship loading, voyage, discharging operation, and warehousing. If sufficient precautions are not observed, this can result in serious problems due to caking of the product. The awareness of personnel involved in transporting and storing of Urea is a prime factor with a view to ensuring that the product is handled, transported and stored, incorporating the measures for preserving its quality. This book highlights important guidelines, characteristics and precautions necessary to ensure proper care is taken to protect the product. Terminal safety, security and hygiene guidelines are also addressed in the book for the benefit of all personnel involved.

Urea ship loading operation

Spell and Disposal Procedures / Accidental Release Measures

Personal protection : Wear protective clothing

Spill : Shovel up and remove. Wash area with water

Environmental precautions

: During hydrolysis, the

Transportation DataUN-no : Not applicableRail / Road / Land waterway : RID / ADR / ADNR

Air : IATASea : IMDGPacking group : Not applicable Numeral and letter : Not applicableDanger class / Division : Not applicable

Regulatory informationHazchem code : NoneLabel : None

Ecological InformationPersistence / Degradability : Urea is biodegradableBio accumulation : Not applicableMobility : Not applicableEco toxicity : Non-toxic

: > 10,000 mg/lLC50 / 96h / Le pomis marochirus : Not applicable

LC50 / 96h / Daphnia : > 10,000 mg/lLC50 / 96h / Nitogra spinipes : Not applicable

LC50 / 120h / Nitzsshia liveries : Not applicable

Additional Information

Urea is also as an additive in cattle feed

Protective Equipment

Eyes : Safety gogglesHands : Rubber glovesBreathing : Dust maskFace : Not applicableSkin / Body : Not applicable

Special protective : Self contained breathing apparatus with full face piece operated in positive pressure mode

General : Not applicable

Emergency and First Aid Procedures

Inhalation: Immediately move to fresh air. If needed, obtain medical help

Eyes contact

: Flush with water immediately and thoroughly. If irritation persists, get medical attention

Skin contact : Flush with water immediately

Ingestion : Rinse mouth with water and get medical attention

Storage and Handling Precautions:

Store in dry condition

Name : UreaFormula : NH2 CO NH2

Formula weight : 60.07CAS No. : 57-13-6UN No. : Not applicable

None

Physical and Chemical PropertiesAppearance : White granules

: 1.34 (Solids), Bulk densityBulk density : 0.75 at 200CWater solubility : Soluble (1080 g/l at 200C)Melting point : 132.70CBoiling point : Not applicableDecomposition temperature : 1330C

Vapour pressure : Not applicableVapour density : Not applicable

pH : Alkaline - 9.5 (100 g/l in water at 200C)

Fire and Explosion Hazard DataHazard Class : Not applicableFlammability : Not applicableFlash point : Not applicable

Auto ignition temperature : Not applicable

Flammable limit in airUELLEL

: Not applicable: Not applicable

media : All extinguishing agents

: Not applicable

procedure

: Wear full protective clothing and self contained breathing apparatus with full face piece operated in positive pressure mode

Reactivity DataStability : StableConditions to avoid : HeatIncompatibles : Strong oxidizers / basesDecomposition products : Ammonia, NOx

Health Hazard DataOSHA PEL : Not applicableTransitional TWATWAIDLH


Toxicity : Not applicableORL-GPG LD50 : Not applicableORL-RAT LD50 : 14.3 mg/kg

: Over exposure of dust may irritate nose and throat























Eyes contact








None










: Not applicable

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Eyes contact








None










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Eyes contact








None










: Not applicable

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2- Material Safety Data Sheet (MSDS) of UREA 7

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Eyes contact








None










: Not applicable

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Eyes contact








None










: Not applicable

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Eyes contact








None










: Not applicable

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Urea ship loading operation

President’s Message

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3- Product Handling:During handling and transport of Urea product, several factors such as human, weather condition and equipment can have an impact on the quality. The following guidelines are necessary to address important factors that affect the quality of Urea:

Material handling equipment like grabs, pay-loaders, hoppers and dumper trucks should be thoroughly •cleaned of contaminants and dry before using them to handle the product.

It is well known that certain weather conditions will seriously affect the free flowing nature of Urea •granules. Hence, loading/unloading operations should be stopped and the ship’s hatch cover should be closed well in advance when there is a threat of product exposure to snow, rain or high ambient humidity.

Hatch covers of holds other than the one being loaded/discharged must be kept closed.•

Spillage of material while loading into trucks must be strictly avoided to prevent contamination, crushing •and powdering. If any spillage occurs, the spilled material should be removed immediately and stored separately.

When any moving machinery is used in the holds, it must be cleaned thoroughly. There should be no •spillage of oil, diesel, etc., on the product.

If any food grain unloading operation is in progress in any adjacent docks, proper care must be taken •to avoid contamination by carryover of grains due to high wind. Similar contamination from any other material should also be avoided.

3.1- Shipping:During cargo loading, transportation and unloading through bulk carriers, the following precautions should be taken to ensure that the quality of the product is protected throughout the handling process:

Ships chartered for transporting Urea should be in a suitably good condition. The interior of the •ship’s holds must be in a well maintained condition, painted, free from rust and loose scale that can contaminate the product.

Prior to commencement of Urea loading operations, the holds must be in a dry condition. There •should not be any possibility of water leakage into the holds.

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View of GPIC Marine Terminal


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Holds must be cleaned thoroughly from the remnants of previous cargo and all the contaminants •should be removed. Corners and crevices must be thoroughly cleaned. Special care is to be taken to remove food grains, if any.

Hatch covers must be air and water tight with no possibility of breathing during long voyages to •avoid ingress of moisture from atmospheric air and condensation on the product.

The ventilating ducts of holds should be closed and bolted tightly during voyage.•

Once the hatch covers are closed at the loading port, they are only to be opened at the discharge •port when the discharge operation from that hold is about to start. Opening the hatch cover during the voyage must be strictly avoided.

Handling of food grains and consumption of food on the deck of the ship during loading/unloading •of Urea must be strictly avoided.

3.2- Trucking from Docks to Warehouse:It is well known that the best mode of transporting Urea is through an enclosed belt conveyor •system.

When trucks are used the Urea should be transported in a covered, fully closed truck, in order to •avoid the product being exposed to atmosphere.

Contamination of Urea due to the movement of trucks inside the warehouse can be avoided by •utilising portable conveyors for stock piling where the truck can unload the material directly into hoppers.

Before truck loading operations commence, the truck must be inspected to ensure that is clean •and in an absolutely dry condition.

Maximum care is to be taken during the movement of trucks inside the warehouse in order to •ensure that the tyres do not come in contact with the product, thus preventing its contamination and crushing.

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Internal view of GPIC Urea bulk storage


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3.3- Warehouse:Urea should be stored in an insulated purpose built warehouse under controlled temperature and •humidity. While taking all necessary measures to protect the product inside the warehouse, special care should be taken to prevent air drafts and ingress of water.

Floors, retaining walls, and crevices must be thoroughly cleaned of previous cargo prior to storing •Urea to avoid product contamination.

Proper care must be taken to avoid contamination by food grains or any organic material.•

Dirt debris and slush entering the storage facility through entry of vehicles into the storage must •be prevented.

Product Urea piles in the warehouse should be covered by plastic sheets.•

Material handling equipment like pay-loaders and dumpers should be used in such a way as to •avoid crushing of Urea granules.

All doors and openings, other than the ones required for transport of Urea, must be kept closed.•

Contaminated and spoiled Urea should not be stored along with good granular Urea.•

Storage of food grains in the same storage and consumption of food in the storage area must not •be allowed.

Temperature and humidity conditions inside the storage while in use for granular Urea must be •continuously monitored and controlled.

Product from storage should be removed on “First in – First out” basis.•

3.4- Transport and Handling of Urea Bags:Granular Urea can be packed, handled and stored in bagged form. To ensure Urea bags are properly handled and transported safely until it reached its end user, handling personnel must be fully aware of the following guidelines to prevent any accidents or spillages of Urea during handling and transportation.

Trucks used should be inspected before loading to ensure it is suitable and safe to transport the •cargo.

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Bagged Urea truck loading


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Trucks should be suitable to carry Urea bags and must be equipped with a fixed side railing and •proper fastening arrangement to secure stacked bags during transport.

Trucks’ stacking surface should be free from sharp edges, nails or any projected parts that can •cause damage to Urea bags.

Trucks should be equipped with enough lashing ropes and tarpaulins during the rainy season.•

While loading the truck, bags should be properly stacked between the side railings. No gaps •between the railings should be allowed through which Urea bags can slip through and fall on the road.

Upon completion of loading, all bags should be properly secured with straps/ropes to avoid •movement during transport.

Ensure the load is evenly and suitably distributed, depending on whether the truck is single axle •or double axle.

Avoid carrying any other product with Urea, especially food products, to avoid contamination.•

On the road, traffic speed limits should be strictly adhered to while driving.•

If there is an accident resulting in bags falling on the road get immediate help to control the traffic •and avoid other vehicles driving over the spilled Urea to avoid skidding.

Do not use hooks while unloading. Hooks will damage the bags and the product will be exposed •and cause caking during storage.

Stacking height at the storage should not be more than 10 bags to avoid products caking over long •period of storage.

Empty bags used for transporting Urea should not be reused for keeping grains and food products. •Damaged bags should be properly disposed off.

Trucks should not be loaded above their allowed load/capacity, so customers should make sure •that the truck provided can load the requested quantity.

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Entrey to Urea jetty


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4.1- Security:

4.1.1- Rules and Procedure:

Ships’ crews are not allowed to enter or exit the GPIC Marine Terminal without authorisation •from the Immigration Office.

Visitors to ships must obtain clearance from the Immigration Office through the ship’s agent •before allowed access.

Goods to and from ships must be cleared by the Customs Officer and inspected by GPIC •Security.

A ship’s crew members are not allowed to proceed from ship to shore without being accompanied •by the ship’s agent/ representatives.

A ship’s crew members must be subjected to a GPIC Security search prior to exit from or entry •to the terminal.

GPIC personnel and contractors are strictly prohibited from receiving or delivering goods/•items to ship’s crew members.

Unauthorised personnel not involved in the loading operation are restricted from boarding the •ships.

4- GPIC Marine Terminal Rules and Requirements:

The GPIC Marine Terminal is a purpose built export facility. It is also an entry and exit port for ships, personnel and goods into and from the country. The Kingdom of Bahrain Rules and Regulations applying to this terminal are similar to other ports within the Kingdom, which are subject to customs and in compliance with the International Ship and Port Facility Security code (ISPS). All personnel who use this terminal are subject to Immigration and Customs Control pertaining to such facilities.

Ships calling at the GPIC Marine Terminal to load Urea must declare their security level according to ISPS code.

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Urea jetty loading office


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4.1.2- Ship-Shore Pre-loading Meeting:

4.1.3- Access to Marine Terminal and Jetty

4.1.4- Precautions for Vehicle Entry

To achieve smooth, efficient and safe operation and so that all security requirements are fully understood and implemented by the ship’s personnel, a meeting is conducted between shore and ship representatives prior to commencement of loading operations.

To facilitate this, shore representatives and the ship’s Master/Chief Officer will jointly fill a number of forms/letters as listed below:

All the above aspects will be discussed and agreed between the ship and shore representatives, any controversial point must be authorised and countersigned by both parties. Also a radio hand set is handed over to the ship for communication during loading operations.

Vehicle entry is restricted to GPIC vehicles. Other vehicles should obtain permission from the •Marine Terminal Security.

While entering the jetty access road, press the buzzer to request the control operator to open •the barrier for access.

Only at emergencies, the barrier can be opened by pressing the ‘Emergency’ push button.•

While entering the access road, watch out for oncoming vehicles from the opposite side.•

Ship/Shore Safety Check List•Agreement on Smoking Locations•Emergency Action Flow Chart•Safety Requirement for Vessels Loading at GPIC Terminal•Ship/Shore Log Sheet•Advise to Open/Close Hatches•Draft Restrictions•Receipt of Product Safety Data Sheet and Guidelines•Movement of Ship’s Crew•Ship Security Plan (Declaration of Security).•Restrictions and Hygiene Requirements.•

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View of Urea ship at GPIC loading jetty


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4.2- Hygiene and AqIS Compliance:

4.2.1- AqIS Guidelines for GPIC Marine Terminal

GPIC Handling and Export facilities are classified as “Level 1 - Gold System Status” for the export of granular Urea by the Australian quarantine Inspection Service. A number of actions and procedures are in place to ensure both the loading terminal and ship personnel, including visitors, are fully aware and adhere to the AqIS system.

All types of seeds, whether used for agriculture purpose or for human consumption, are strictly •prohibited within the loading and export premises.

Consumption of food, including fruit which contains seed, is strictly limited to authorised areas •inside buildings i.e. mess rooms, tea rooms and kitchens. No food consumption is allowed in open areas at the storage and loading facilities.

All areas where food is consumed must be cleaned on a daily basis and trash must be contained •and disposed off properly.

The use of natural coir brushes or brooms for cleaning purposes is strictly prohibited within the •loading terminal or close to the product’s handling facility.

Areas around and inside the storage, transfer conveyors, transfer towers and jetty •platform should be kept clean and tidy. Foreign material that can contaminate the

product should be removed immediately and disposed-off properly.

All handling equipment such as conveyor belts, scrapers, •chutes, etc. should be cleaned thoroughly before use.

The maximum speed limit is 30 km/hr.•The maximum vehicle axle weight is 16 MT.•Maximum total vehicle weight is 35 MT.•

On the jetty platform, vehicles must be parked in the designated parking area.•

Limits on the jetty access road:•

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Booting operating thru control room


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4.2.2- AqIS Regulations and Guidelines for ShipsShip holds must be clean and ready for loading prior to vessel arrival at loading port. Hold •cleaning or disposal of any waste matter is not allowed at berth. Loading will be commenced after all holds are inspected and passed by an independent surveyor.

Urea product loaded into the ship will be sampled regularly by an online automatic sampler to •ensure the product quality is monitored throughout the loading operation.

For ships calling at Australia, holds will be inspected according to the procedure laid out by •(AqIS). A buyer surveyor normally appointed along with the terminal independent surveyor who will inspect the holds using a cherry picker/ man bucket. The inspection of ship holds will cover the entire holds and all the crevices between the internal structures of the holds. Holds must be free of objectionable material mentioned under the AqIS protocol, such as seeds, grain, organic matter, wood chips, animal products, etc. Ships are advised to ensure all holds are thoroughly cleaned prior to their arrival at loading port.

A man bucket/ cherry picker may be provided by GPIC under normal circumstances, subject to •availability. A man bucket/ cherry picker can be hired by the ship through their local agent. The ship will arrange to lift and place the man bucket into the holds as directed by the surveyor.

Inspection of ship holds before loading is sometimes carried out with the aid of a man-bucket •which must be thoroughly cleaned of any contaminants before placing inside the holds.

For any delivery of food or supply of material to the ship, the inspection of all deliveries should •take place at the terminal’s security. Loose material or material not properly packed or sealed will not be allowed to proceed to the jetty area.

The ship should maintain good cleanliness and hygiene on the deck and around the holds. •There should be no obstructions on the deck that will prevent free movement of the shore personnel involved in the loading operation.

Fishing is not permitted while the ship is alongside. Consumption of food, drinks and smoking •is strictly prohibited outside the crew quarters.

No dirty ballast should be discharged into the sea. The ship must meet the local regulations •pertaining to pollution of the sea water. and ballast water management.

The Master of vessel is responsible for complying with all the terminal regulations, port •regulations and the local laws.

Note:

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Issue 2 - January 2012Gulf Petrochemical Indusries Company,(BSC)P.O.Box 26730, Manama, Kingdom of Bahrain Tel: +973 1773 1777 - Fax: +973 1773 1047 Email: [email protected] Website: www.gpic.com

final version lr 29 dec 2011

Documents

product handling

handling of urea bags

storage of granular

aqis guidelines

highest quality

gpic marine terminal

export operations

export activities