Tuesday, February 27, 2024



The Risk Assessment For Storage And Handling Of Hazardous Chemicals & Solvents uploaded by HSE Documents highlights how Hazard identification and prevention measures are crucial prerequisites before the storage and handling of hazardous chemicals and solvents due to several compelling reasons. Firstly, these substances possess inherent properties that can pose significant risks to human health, the environment, and property if mishandled or improperly stored. Chemicals and solvents can be toxic, flammable, corrosive, reactive, or possess other hazardous characteristics. Without proper identification of these hazards, individuals working with or near these substances may unknowingly expose themselves to serious health hazards or ignite catastrophic accidents. Therefore, thorough hazard identification is imperative to understand the potential dangers associated with each chemical or solvent and to develop effective preventive measures to mitigate these risks.

Secondly, implementing prevention measures based on hazard identification is essential to safeguard personnel, facilities, and the surrounding environment from potential harm. Prevention measures encompass a wide range of strategies aimed at minimizing or eliminating hazards associated with the storage and handling of hazardous chemicals and solvents. These measures may include engineering controls such as ventilation systems, containment measures, and safety equipment like personal protective gear. Additionally, administrative controls such as standard operating procedures, training programs, and emergency response plans play a vital role in preventing accidents and minimizing the impact of chemical hazards. By systematically identifying hazards and implementing appropriate prevention measures, organizations can create safer work environments and reduce the likelihood of incidents that could result in injuries, environmental contamination, or property damage.

Finally, hazard identification and prevention measures are indispensable components of safe chemical handling and storage practices. By proactively identifying potential hazards associated with hazardous chemicals and solvents, organizations can develop robust prevention strategies to mitigate risks effectively. These measures not only protect the health and safety of workers but also safeguard the environment and surrounding communities from the adverse effects of chemical accidents. Therefore, regulatory authorities, industry stakeholders, and organizations must prioritize hazard identification and prevention efforts to ensure responsible and safe management of hazardous chemicals and solvents.

1. Process/Activity

1.1. Transportation of raw material and chemicals

1.2. Unloading of material from road tanker/truck

1.3. Storage of raw material and finished product Use of electrically operated machines and pumps

1.4. Use of electrically operated machines and pumps

1.5. Degradation or contaminated by incompatible material. Uncontrolled reaction.

1.6. Disposal of solid and hazardous waste like packing material and used chemical drums.

1.7. Reactor operation

1.8. Storage and handling of finished goods.

1.9. Operation of DG set and rotating machines

2. Hazard involved

2.1. Spillage of material during transportation.

2.2. Leakages of liquid material during transfer– unloading using hose. Risk of fire.

2.3. Spillage of material during handling. The material may catch fire as some chemicals like Pyridine, Ethanol are flammable. Health risks in case of contact with material

2.4. Hazards due to electrical shock

2.5. There is a risk of runaway reactions leading to potential product quality degradation and the production of hazardous process waste.

2.6. Exposure to toxic remains of material. Critical harm whilst dealing with solid and risky liquid chemical and or substances waste drums.

2.7. Overheating of material may cause runaway reaction and generation of hazardous waste due to bad quality of material. Spillage of substances, material, chemicals during the transferring and charging the material to reactor. Accumulation and creation of vapors and or fumes while charging liquid chemicals or other substances methylene chloride (CH2Cl2) to reactor. 

2.8. Chances of spillage while transferring from reactor to storage drum or container. Chances of accident while transporting the goods.

2.9. Generation of noise due to rotating machines/DG set.

3. Risk

3.1. Exposure of the liquid chemical can cause injuries and burn. Especially acetic acid, Pyridine, Hydrochloric acid etc. The liquid material (chemicals) spillage can cause and generate various types of pollutions such as land, air and sea pollution due to spread of vapors of the chemicals.

3.2. Exposure to toxic vapors and fumes as highly hazardous materials like acetic acid, ethanol, and P- toluene sulphonic acid is handled. Health risk to workers

3.3. Exposure to toxic vapors and fumes. Health risk to workers. Risk of catching fire

3.4. Electrical shock can result in serious injury or can be fatal

3.5. Risk of fire, injury and health problems to workers.

3.6. Health effect and minor injury

3.7. Health risks to employees involved working in the reactor. The critical occupational health risk due to inhalation of toxic substance’s vapors while charging the material in the reactor.

3.8. Injury to workers. Health risks are also involved.

3.9. Impairment of hearing

4. Control Measures

4.1. Spillage of material during transportation:

4.1.1. Ensure proper packaging and securing of containers to prevent spillage.

4.1.2. Train personnel in safe handling practices during transportation.

4.1.3. Use spill containment measures such as spill kits and absorbent materials in vehicles.

4.2. Leakages of liquid material during transfer– unloading using a hose. 

4.2.1. Implement regular inspection and maintenance of hoses and transfer equipment.

4.2.2. Use hoses equipped with safety features like leak detectors and automatic shut-off valves.

4.2.3. Provide fire-resistant barriers and equipment in transfer areas.

4.2.4. Conduct training on proper transfer procedures and emergency response protocols.

4.3. Spillage of material during handling:

4.3.1. Provide adequate training on proper handling techniques.

4.3.2. Use spill containment trays or barriers around handling areas.

4.3.3. Ensure the availability of personal protective equipment (PPE) for workers.

4.3.4. Store flammable materials in designated areas with appropriate ventilation.

4.4. Hazards due to electrical shock:

4.4.1. Implement regular inspection and maintenance of electrical systems.

4.4.2. Install ground fault circuit interrupters (GFCIs) in areas where water or chemicals are present.

4.4.3. Provide training on electrical safety procedures.

4.4.4. Use insulated tools and equipment when working on electrical systems.

4.5. Possibility of runaway reaction:

4.5.1.  Implement process control measures such as temperature monitoring and automatic shutdown systems.

4.5.2. Conduct thorough process hazard analyses to identify and mitigate risks.

4.5.3. Provide emergency response training for personnel.

4.5.4. Ensure proper ventilation to control the buildup of hazardous vapors.

4.6. Exposure to toxic remains of material:

4.6.1. Implement proper waste management practices for handling and disposal of toxic materials.

4.6.2. Provide personal protective equipment (PPE) such as gloves, goggles, and respiratory protection.

4.6.3. Conduct regular monitoring for exposure levels and implement controls accordingly.

4.6.4. Train personnel on safe handling and disposal procedures.

4.7. Overheating of the material may cause a runaway reaction:

4.7.1. Implement temperature control measures and monitoring systems.

4.7.2. Conduct regular maintenance of heating equipment and reactors.

4.7.3. Provide emergency cooling systems and procedures.

4.7.4. Train personnel on safe handling procedures for volatile chemicals.

4.8. Chances of spillage while transferring from reactor to storage drum or container:

4.8.1. Use closed transfer systems to minimize the risk of spillage.

4.8.2. Implement proper labeling and handling procedures for containers.

4.8.3. Provide spill containment measures such as secondary containment systems.

4.8.4. Conduct regular inspection and maintenance of transfer equipment.

4.9. Generation of noise due to rotating machines/DG set:

4.9.1. Implement engineering controls such as soundproofing or noise barriers.

4.9.2. Provide hearing protection devices for workers.

4.9.3. Conduct regular maintenance of machinery to minimize noise levels.

4.9.4. Rotate workers to minimize prolonged exposure to high noise levels.

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