Driver Product & Safety Training MDI / TDI Bulk Liquid ...isopa.org › media › 2064 › en-speakernotes.pdf · 3 ISOPA Driver Training Program 3 Revision 2019 Background MDI

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ISOPA Driver Training ProgramRevision 20191

Driver Product & Safety Training

MDI / TDI Bulk Liquid Transportation


This driver training package was first developed in 2000 by ISOPA, in cooperation with the transportation companies for drivers and those active in the logistics supply chain in line with the Responsible Care ® principles, to help ensure the safe loading, transportation and unloading of isocyanates. More than 6,000 drivers have been trained since then.This package should be used by dedicated trainers who have undergone a training session organised by ISOPA. For more information contact [email protected] or your MDI / TDI supplier.Based on the attendance list, ISOPA will dispatch signed certificate cards for drivers who have successfully completed the programme. Certificates are valid for 3 years. The ISOPA driver training package contains a slide show and a questionnaire file, which also includes the required attendance list. Attendance lists and slideshow can be obtained from: http://isopa.org/product-stewardship/logistics/driver-training-for-carriers/ in a variety of languages.The slideshow contains 55 slides. The videos and DVDs mentioned in these slides can be obtained through an order form on the same website. It is recommended to print the Speaker notes, included in the slideshow, and read them carefully before the package is used. The Questionnaire is a multiple choice test, of which the trainer can select 20 relevant questions dependent on the haulier, mode of transport, and type of diisocyanate. Mark the selected questions in column A and use the counter in cell A1 to ensure you have 20 questions. Use the filter button in cell A3 to retrieve the final questionnaire.The questionnaire is in columns B-I (print pages 1-2). Trainers should contact ISOPA to obtain the link to the answers.Column K contains a reference to where in the slide package the specific question is dealt with.Procedure:[1] For each session: make sure all attendants are listed on the attendance list, print the list and obtain their signatures; the trainer should also sign the list.[2] After the test, mention on the attendance list the obtained score of each attendant.[3] In order to obtain cards enter the data of the persons who have passed the test into: http://drivertraining.isopa.org/[4] Send a copy of the signed attendance list - including the obtained scores - to ISOPA (either a scanned copy by e-mail, or a hard copy by ordinary mail).No certificates will be issued until copy of the signed attendance list is received.

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Driver Training MDI / TDI

Company [name]

Location [place]

Date 21/06/19

Trainer [name]

This slide to be used as an opening slide in which the company, the venue and the trainer’s name can be inserted.

It is important to have an attendance list which can later be used for audit purposes.

• An example is included in the questionnaire file.

• Don’t forget to mention the names of the carrier(s) drivers work for.

33


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

44


Introduction ISOPA

European

ISOcyanate Producers Association

See website www.isopa.org

Member companies:

olyo

5


ISOPA Member Companies

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66


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

Polyurethanes are used to make the following products

and articles:

• Automotive – Car seats and parts such as

steering wheels

• Footwear – Sports shoes, boots

• Furniture and Bedding – Sofas, chairs and mattresses

• Binders – Wood products such as fibreboard (MDF) for construction and furniture

• Adhesives and Sealants – Sports surfaces, expansion joints and gasket seals

• Appliances – Refrigerators and freezers

• Building and Construction – Energy saving insulation foam

• Coatings – Metal protection for cars and concrete protection for buildings

77


Appearance

Liquid Reacted

MDI Clear to brownSlightly musty

BrownCrusty

TDI Clear to pale yellowSharp, pungent

WhiteFoamy

88


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

1 mg/m3 = 0.14 ppm

1 ppm = 7.11 mg/m3

1 ppb = 0.001 ppm

99


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!

1010



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.)

Density:

Before loading it is important to realise that the DENSITY is in the range of 1.20 – 1.29:

• Prevent overfill - max. 95 %

• Minimum 80% filling degree (without baffles): ADR requirement for TDI, is also strongly recommended for MDI

• Careful at roundabouts!

Vapours:

Be aware of vent stacks, vapour return outlets etc.

Critical Temperatures:

These are approximate values; actuals may vary depending on product/grade

1111


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

1212



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

Check temperature at every rest break - inform planning department if temperature is rising “on its own”, and in any case if temperature with / without heating exceeds 50°C.

Pressure check only if you can do this safely (working at height) !

13


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 !

This slide contains a list of the symptoms which can occur due to exposure.

These symptoms can become evident up to a day after exposure and so there should be careful monitoring to pick up the signs of exposure after the incident.

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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

There is a risk of sensitisation from even a single exposure to a high level of MDI vapour. In a sensitized person even a further low level of exposure can result in severe asthmatic symptoms.

14

1515


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

Inhaling TDI (or MDI) vapours can make breathing very difficult.

1616


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

Inhaling MDI (or TDI) vapours can make breathing very difficult.

1717


Product Transport Use

MDI Not regulated but still harmful

TDI ADR / RID / IMDG

UN 2078

Class 6.1

Packing Group II

Marking and Labelling:

ADR tunnel category: (D/E)

Classification and Placarding

602078

1818


PPE – MDIPersonal Protective Equipment

Hard hat Goggles Liquid-tight gloves Safety shoes / boots Long-sleeved overall Eyewash bottle

As a minimum...

• Butyl rubber• Neoprene• Nitrile rubber

1919


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

2020


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

isocyanatesYou should not use

contact lenses when handling

isocyanates

2121


Personal Health (1)

Use an appropriate cartridge / canister (min. AP2)

For normal use, once opened, use max 8 hours within any 48 hours time span

After any spill change the cartridge

Face mask should not be used for Emergency Response

Use full face respirator according European standard EN 136, combined with cartridges equipped with standard DIN thread (40 mm) EN 148-1 or gas and combined filters according EN 141. Attention:

This standard has been replaced by EN 14387 Note:

If powered systems (motor blowers + filters + full face respirators) are used they should comply with EN 12942.

If sealed: watch validity date stamp - do not use if expired;

Once opened: do not use for more than 8 hours in total within any 48-hour

time span; put seal caps back in position between shorter usage

periods. Even a 3-day beard affects the face seal and reduces the effectiveness of the mask ! Do not use same filter for different products. Next product may wash out the previous one into the air breathed in by the wearer!Filter to be replaced after 2 days unless different guidance from supplier Filters need to be discarded 48 hours after use because:

Filters are activated carbon; the activated carbon adsorbs the product.

Oxygen and water vapour present in the atmosphere will also be adsorbed and will reduce the capacity of the filter.

2222


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 !

2323


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)

Certificate of Analysis:

CoA is strongly preferred to a sample; best of all a copy should be faxed or mailed beforehand.

Samples (pvc / glass / alu / etc.):

If a sample is inevitable then it should be sent separately.

• If customer / customs insists on taking a sample from the road tanker or tank container, then this is only allowed if relevant safety measures have been taken.

• Preferred sampling method is via a customer controlled, closed system.

• DRIVERS SHOULD NOT TAKE SAMPLES ! Therefore: Call your planner first in case you are still asked to do so.

Temperature:

Upon arrival, product to be delivered must meet customer’s requirements, which will depend on their production process!

2424


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

2525


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 system

2. Absorb the spill

3. Wait (15 minutes)

4. Neutralise

5. Wait (30–60 minutes after reaction has finished)

6. Remove spill after reaction has finished.

7. Put residues in designated chemicals waste bin

8. Apply decontamination fluid

4. NeutraliseNeutralising before absorbing increases the risk of sewer (or environmental) contamination

3-5. WaitReaction of isocyanates, as discussed, consumes water (moist) and produces carbon dioxide. Hence “reaction” of the isocyanate during an emergency and will be visible in the form of bubbles or “lively foam”. Once the bubbles have stopped you should still wait 30 minutes for the last traces to react.

Cleaning up before the reagents are consumed means carbon dioxide gas will be produced in the waste bins. This carbon dioxide will be driven out of the waste bin entailing toxic or hazardous fumes or when kept tight, it will pressurise and explode.

7. ResiduesDo not close the waste bin.

2626


Loading: Key Items

PPE must be worn

Tank equipment

3-Minutes check before & after loading

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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)

A US study (BLS.gov 10 11 07) showed that of the 65,930 non-highway injuries of truck drivers in 2005 - 2006 14,800 (22%) are related to falling from heights and another 13,000 injuries happened due to falls at the same level. Moreover, 1 in 1,000 of these injuries leads to a fatality.

If the risk cannot be eliminated, a gantry provides the most safe conditions for working at height. Gantries are mainly seen in high volume operations; e.g. frequent loading at suppliers’ sites or storage terminals. Cages are mostly used at medium chemicals customers for loading or unloading activities. Gantries or cages may not always be practicable for economic or site layout reasons. Mobile stairs provide an alternative and are frequently used at smaller chemicals customers for unloading activities. The disadvantage of a mobile system is that it requires discipline from the operators to follow the instruction to actually use it.

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If a gantry or cage is not available, the use of a fall

arrest 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)

Preferably drivers have to have their own harness that are fitted to their size. Harnesses provide adequate protection to the drivers, as long as the following conditions are met:

• Harnesses need to be inspected in accordance with applicable legislation

• Drivers need to visually inspect their harness for defects and damage before each use

• Drivers need to be trained in how to wear their harness

It is recommended that carriers provide harnesses to the driversand that loading / unloading sites have harnesses available as back-up and for use in exceptional circumstances.

Sites should have a rescue plan, in case an operator or driver falls from the vehicle and is suspended in his safety harness. The plan will help to ensure a quick response and avoid a potentially hazardous improvised rescue operations.

For an example go to: http://www.osha.gov/dts/shib/shib032404.html

Self lowering fall arrest systems significantly reduce the likelihood of suspension trauma and make the creation of the site’s rescue plan easier.

2929


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!)

Ensure tank space is sufficient to receive the order volume.

A sticker has been created to put on the manhole, to indicate that the manhole must be kept closed. The sticker is available from ISOPA and shown here.

Tanks should be kept carefully sealed, product protected from frost and contact with moisture.

MDI / TDI reacts with moisture producing carbon dioxide (CO2) causing an increase in pressure which may rupture

closed containers; the reaction also increases the product temperature (check regularly!).

If no vapour return system is available, then be aware that the tanker is likely to be pressurised. The overpressure should be released to a minimum (< 0.1 bar) before leaving the supply point: pressure upon departure should preferably be similar to the pressure upon arrival!

3030


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

Temperature inside the tank should be 18 °C minimum to avoid solidification.

3131


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?

3232


Transport

Hours / Speed

Check temperature (and pressure)

Reporting unsafe conditions / incidents

Parking

Hours / Speed Regulatory compliance is crucial. Report delays.

Check Temperature (and pressure)These should be performed at regular intervals, and recorded.

Reporting unsafe conditions / incidentsAll unsafe conditions and near misses must be reported to avoid incidents.Non reporting will eventually result in an incident.

3333


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/

Letter to Customs Officials,

This road tanker / tank container contains or has contained a diisocyanate (TDI – toluene diisocyanate or MDI – diphenylmethane diisocyanate). This chemical is used in the manufacture of polyurethanes.

The tank contains TDI or MDI vapours. These vapours can cause a strong asthmatic reaction if they are breathed-in. This condition can last a life-time. Any symptoms may take up to 24 hours to develop. All chemical workers are trained to never breath-in these vapours and, if there is a danger of exposure, they wear breathing apparatus.

At certain discharge installations nitrogen is used to empty the container. Nitrogen is an asphyxiating gas and the lack of oxygen is not mitigated by using a gasmask filter.

As diisocyanates react with moist from the atmosphere, the opening of the manlids will, in addition to the above health effects, have a negative effect on the inside of the container and ultimately will result in more frequent cleaning with a negative impact on the environment.

Any entry into the tank, such as for an inspection, must not be done without proper protective equipment, which, as a minimum, consists of breathing apparatus, long sleeves and gloves. Please consult the supplier’s Safety Data Sheet (SDS) before opening the tank.

There is always a risk that the tank is under pressure either because of the discharge or because of the reaction of the diisocyanate with moisture. Only a slight overpressure could result in serious injuries. Therefore, always depressurise the tank before opening the manlid.

Any opening of the manlids or entry, with or without proper protective equipment, is the responsibility of the person doing so. Neither the supplier of the diisocyanate or the owner of the tanker will take the responsibility for any health effects nor damage occurred by entering the tank. Yours Faithfully

ISOPA Secretary General

3434


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

Information on customer, route or destination – if in the wrong hands – may enable others to plan undesired action.

3535


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)

For this reason the application of the do-not-open-the manlid sticker is critical.

Also the heating itself needs to be done slowly.

The maximum product contact temperature is 60°C.

For that reason - if steam is used - a maximum steam pressure of 1.7 bar ( which produces condensate at 115°C) is to be used.

For steam only external heating coils are allowed to eliminate the risk of steam leaking into the product (water will react with TDI / MDI).

Overheating of TDI will cause trimerisation (a reaction of 3 TDI molecules combining).

This trimerisation is "exothermic" ( the reaction produces heat).

This will ultimately lead to the production of CO2

(carbon dioxide), and therefore pressure increase which possibly leads to tank rupture.

A similar dimerisation reaction of MDI will also produce CO2.

3636


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)

Behaviour / Site Regulations

Behave as a guest and remember you are the supplier’s representative!

Follow all site (safety) instructions and ensure there is a mutual understanding of the discharge process between you and the operator.

In case of a dispute, contact your planning department and do not start unloading.

Unsafe conditions at a customer must be reported.

Try to avoid sampling from the tanker by explaining to the customer that your company does not allow you to do this, but if still required to do so: contact your planning department. Sampling is regarded to be a high risk operation!

3737


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)

Pressure Discharge:

Towards the end of the discharge reduce the pressure to avoid a pressurised tank when in transit and before next loading. Of course it is dependant on physical circumstances at the various customer sites whether this can be achieved. Ideally, the pressure after discharge should be roughly the same as before!

PPEAlways wear your PPE with a minimum of hard hat, safety glasses, safety shoes, gloves & overall. In case of TDI: wear full face mask during (dis)connecting.

Transport document

Suggest to record on the transport document :1.Delivery temperature.2.Pressure left in tanker after discharge.

3838


Discharge Methods (1)Customer liquid pump and vapor return

(Preferred option is a close system with hoses provided by customer)

Recommended according to ISOPA Bulk Guidelines

Discharge methods are shown in decreasing order of preference.

1.Customer liquid pump and vapour return

2.Customer nitrogen or dry air

3.Vehicle compressor

Pumping equipment and hoses should preferably be available at the customer’s site.

Additional advantage is an increased payload.

3939


Discharge Methods (2)Customer nitrogen or dry air

Not in line with ISOPA Bulk Guidelines

Not in line with ISOPA guidelines for safety & environmental raisons





Nitrogen, dry air and hoses should preferably be available at the customer’s site.

Additional advantage is an increased payload.

4040


Discharge Methods (3a)Vehicle compressor with silica gel

Not in line with ISOPA Bulk Guidelines

Not in line with ISOPA guidelines for safety & environmental raisons





Hoses should preferably be available at the customer’s site.

Discharge with a compressor, even with a silica gel filter, will introduce moist in the tank.

Isocyanates + water Solids in the next delivery

As a hydroscopic substance, silica gel is supposed to dry the air which is passing through a silica gel filter. However, due to the fact that:• the total quantity of ambient air required for a pressure discharge is passing through at a high speed, and

• compressed air from the vehicle compressor is likely to become very hot, and• heat is used to regenerate used silica gel crystals,

the useful (drying) effect of silica gel filters on transport tanks is at least very doubtful.

4141


Discharge Methods (3b)Vehicle compressor without silica gel

Improvements highly recommended


1.Customer liquid pump and vapor return



Hoses should preferably be available at the customer’s site.

Discharge with a compressor will introduce moist in the tank.

Isocyanates + water Solids in the next delivery

4242


Spillage Tray Lay-out (example)

Liquid line and vapour return line

should be properly identified

Vapour

LiquidPressure

Silica gel filter is not shown here.

You could insert a picture of your own equipment here.

4343


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?

Make sure the transport document is completed with relevant details before it is presented for signing by the customer:

• Time of arrival and departure

• Delivery temperature

• Any damages

4444


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

ADR 5.4.1.1.6.2.3Special provisions for empty means of containment, uncleaned

When empty means of containment, uncleaned, which contain the residue of dangerous goods of classes other than Class 7, are returned to the consignor, the transport documents prepared for the full-capacity carriage of these goods may also be used. In such cases, the indication of the quantity is to be eliminated (by effacing it, striking it out or any other means) and replaced by the words:

“Empty, uncleaned return”

4545


Near Misses & Unsafe Conditions

Iceberg Theory

Near misses & Unsafe conditions

Incidents

Active Near Miss reporting will reduce / avoid serious incidents.

Iceberg theory

Research showed that there is a relation between serious incidents, less serious incidents, incidents with only material damage and near misses.

An active near miss reporting and follow up allows appropriate action and will reduce / avoid the more serious incidents.

Near Miss definition:A near miss is a situation with potential consequences in the area of safety, health, environment or business continuity in which a conscious action of recovery OR LUCK has prevented damage or injury.

1. Serious incidents

2. Less serious incidents

3. Incidents with only material damage

4. Near misses

1

2

3

4

4646


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

Regular temperature checks are of vital importance, but always check when stopping for a meal or rest period!

Unexpected temperature rise may occur as a result of polymerisation, or contamination with water. Always report this to the planning department, who must consult the supplier immediately!

Unsecure routing: keep to motorways / highways if possible and avoid residential areas where possible.

4747


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 !)

Most incidents and accidents occur during loading or unloading!

However, as explained, isocyanates can be handled safely; programmes such as this training will help in the safe transport of these chemicals.

48


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

Some important First Aid tips

If there is any suspicion that MDI/TDI has got into your colleagues eyes flush with water. The flushing with water will not be pleasant but continue for 15 minutes. The alternative is much worse. An eye specialist MUST be consulted.

If MDI/TDI has got to your or a colleague’s skin – wash the area many times with soap and water

Fresh air helps recovery.

The patient/victim must see a doctor.

The doctor should be knowledgeable about MDI/TDI effects but more information to help the doctor can be obtained from your MDI/TDI supplier.

Is your local doctor knowledgeable about MDI/TDI?

48

49


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

5050


And ......

In any case of emergency:

call us ....

don‘t try to be a hero.....!!

5151


Emergency Response

TDI

Danish incident

French incidents

Portuguese incident

Swedish incident

Turkish incidents

Hungarian incident

Belgian incident

MDI

British incident

German incident

Italian incident

– Packed

– Bulk

– Bulk

– Bulk

– Bulk

-Bulk

-Packed

– Bulk

– Bulk

– Bulk

Videos can be viewed here

http://isopa.org/product-stewardship/logistics/emergency-exercises/

5252


Emergency Response

Emergency incident scenario

– What went well ?

– What can be improved ?

Trainer must be aware of the contents and should list all the pro’s and con’s before showing this video to the audience.

Before showing the video ask audience to list their observations, positive and negative.

Show the video.

Discuss observations.

Show video again to confirm observations as a learning curve.

Note:Summarise learning curve and list possible actions to be taken when an emergency arises.

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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

Test

Show this slide as an introduction to the test, and leave it on display until everyone has handed in the test.

Discuss the test

Once everyone is ready, go through the questions and give the right answers. Be prepared for discussions; see the cross reference table (on the right of the Correction Matrix) where you will find indication of the slide(s) involved for each question.

Use the next slide as a “Pay-off” to mark the end of the session.

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The End

Congratulations!

Certificates will be forwarded as soon as possible

Details of those who passed are to be sent to ISOPA (example of report list included in Test Questionnaire File) who will send certificates in return.

Guidelines on how to obtain driver training cards can be found on the ISOPA website:

http://drivertraining.isopa.org

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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

Documents

Driver Product & Safety Training MDI / TDI Bulk Liquid ...isopa.org › media › 2064 › en-speakernotes.pdf · 3 ISOPA Driver Training Program 3 Revision 2019 Background MDI