R-1Copy of Guidelines for Safe Transportation of Chlorine Tonners

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TransportationOf

ChlorineTonners/Cylinders

Presented by:

H. S. Sehgal

DGM (Process)



OVERVIEW

As on today 70,000 chemicals have been identified for

industrial and domestic applications and there is

addition of 3000 chemicals per year.

More than 3500 chemicals have been classified andlisted in central motor vehicles rules.

Compressed gases filled in 0.5 ltr to 1000 ltr. Cylinder

falls under the classified category.

Many industrial and laboratory operations require theuse of compressed gases for a variety of different

operations.



Conti«

Careful procedures are necessary for handling the various

compressed gases

In India road transport is the favorite mode of transportation for

compressed gases. More than 3 lacs accidents are taking place

per year resulting 88,000 fatalities and 102 million injuries. Thisresult is direct economic loss of 700 crorers and national loss

of Rs. 55000 Crores. Consequences are disastrous when

vehicles involving is carrying hazards goods.

In order to improve road safety it is important that the consignator,

consignee, the hauler, the vehicle driver and all the concerned

authorities do their best to achieve this goal. So that we can have

comparable road safety standards as in the developed countries



Dangerous Goods

Dangerous Goods are S ubstances and Cargo, which, based on

their

- nature,

- properties, and behavior as well as

- conditions,

may cause, during the transport, a H azard in particular to

- the public safety ,

- the health of the people,

- the damages and loss of the infrastructure and equipment, also

-the negative effe

cts and

contamination to the environment

When transporting Hazardous Chemicals which are classified to

be ³Dangerous for transport´ into one of the total 9 classesbased on the UN Classification Criteria,

these Hazardous Chemicals are called ³Dangerous Goods´.

4



CLASSIFICATION OF CHLORINE

It has a Class 5.1.2A oxidizing gas hazard

classification.

Acutely toxic (Class 6. 1A)Toxic to human target organs (Class 6. 9A)

Corrosive to metals (Class 8. 1A)

Corrosive to skin tissue (Class 8. 2A)Corrosive to eye tissue (Class 8. 3A)

Very eco-toxic to aquatic and soil environments

(Classes 9. 1A, 9. 2A) .



System of Linkage

http://www.unece.org/trans/danger /danger.htm

International Regulations

for Dangerous Goods Transport System

Multi-modal Transport: UN

Recommendations on the Transport

of Dangerous Goods: a so-called

³UN Model Regulations´ or ³Orange

Book ́

Road: The Restructured ADR of

UNECE in Geneva,

Rail: The Restructured RID of OTIF

in Bern,

Inland Waterways: The

Restructured ADN of UNECE inGeneva,

Sea: IMDG Code of IMO in London,

Air: I ATA-DGR of ICAO-TI of ICAO

Montreal

6



INDI AN REGULATIONS

Manufacture, Storage, Import & HazardousChemicals Rules, 1989

Chemical Accidents (Emergency Planning,Preparedness and Response) Rules, 1996

Public Liability Insurance Act, 1991 Public Liability Insurance Rules, 1991 Factories Act 1948 Gujarat Factories Rules 1963, as amended

1995

Motor Vehicles Act, 1988 and Rules 1989



UN

Recommendations

on the Transport of

Dangerous Goods

Classification of

Dangerous Goods

List of Dangerous

Goods most

commonly carried

Packing

Packaging

Intermediate Bulkcontainers

Multi-modal TankContainers

Consignment

Procedures

Definition of classes/divisions

Test methods and criteria

Name and UN Number

Main hazard and subsidiary risk

Transport conditions

Labeling

Assignment of packing group

Packing methods

Special provisions

Multi-modal tank transport

Construction requirements

PlacardCertification and approval

Marking

Labeling

Transport documentation

Exemption quantities

Modal Requirements

Danger specific to one

mode

Restrictions

Types of packaging allowed

and quantity limitations

Specific marks

Specific LabelingSpecific items of information

Special exemption

Types of tanks allowed

UN Rec. or TP1UN Rec. or TP1 TPTP22 && 33 = TP= TP11

++

Key contents of Dangerous Goods Regulations

8



Key Responsibilities

Parties involved in the chain of transport of dangerous goods:

Consignor

Packer

Loader

Carrier

Consignee

Packers

Fillers LoadersCarriers

(

Drivers

ConsigneeConsignor

)



Prior to transport

- Consignor

- Loader

Packer/Filler

Tank-container /

portable tank operator

During transport

- Carrier

Driver

Af ter transport

- Consignee (

Take appropriate measures to reduce or minimize the risk from transport

Receive training in the requirements governing the carriage of such goods

appropriate to their responsibilities and duties (Chapter 1.3)

Saf ety obligations of the participants of the

transportation process

10



Case Study of good practices



Gate Check

Process of the checking of vehicles carryingdangerous goods

Check Order Number of Dangerous Goods

Check Transport Number of Dangerous Goods

Identified Card/Passport of Driver

Driver¶s training certificate

Driving License

ADR Certificate

Weighting of vehicles

Check before exit ± joints & couplings, alldocumentation

TREMCARD

12



RiskManagement Project ProjectManagement Board (PMB) 13

TREMCARD



Inspection of Vehicle

Orange Plate

Tires Depth (1.6

cm.)

Tank Code

14



Inspection of Equipments

Pocket Lamp (Explosion Proof)

Fire Extinguisher

Goggles

Gloves

Eyes-Wash Bottle with CleanWater

Scotch or wheel-chock

2 reflective triangles

15



Inspection of Driver

Alcohol

Drugs

16



Inspection of Driver

Alcohol

Drugs

17



Check list During Transportation

(a) Breaks CHECKED.(b) Speed LIMIT.

(c) Driver not UNDER INFLUENCE of liquor.

(d) Check for leakage with ammonia torch.

Check list During Unloading

(a) Vehicle breaks APPLIED and engine STOPPED.

(b) Under SUPERVISON of trained and experienceperson.

(c) Crain/hoist/chain pulley block USED.

(d) NO DROPPING of tonners DIRECTLY to theground.



GLOBAL MODE OF CHLORINE

TRANSPORTATION

Rail TransportNorth America 80 Tonnes Rail CarsEurope 55 and some 22 Tonnes Rail Cars Japan 25 Tonnes Rail Cars

Road TransportNorth America 16 Tonnes TrucksSouth America 18-22 Tonnes TrucksEurope 20 Tonnes Trucks and Containers

Japan 10 Tonnes Trucks & some 5 Tonnes or less

Water TransportNorth America 1000 Tonnes Barges



GLOBAL TRANSPORTATION SCENARIO

Worldwide other modes of Transportation are also being used like thro Barges onW

ater for more than 6000 kms distance in Columbia, Chile & for very shortdistances, Pipelines

Country Quantity of Cl2

Transported(% of Production)

Mode of

Transport

Max. Distance

Covered(Kms)

NorthAmerica

35 Rail (90%)

Road (6%)

1000

SouthAmerica

66 RoadRail (75%)

4000 (Brazil)1500 (Chile)

Japan 10 Rail (30%)

Road (70%)

600

300

Europe 6 Rail (67%)Road (33%)

1000200

India 51 Road (100%) 1200





STATUS OF INDIAN CHLORINE

INDUSTRY

Most Chlor-Alkali Plants : Merchant & Non-Integrated

Production Plants are widely spread

Most Consumers widely spread

Maximum Cl2 transported in small Cylinders / Tonners by road (51%) with max. 1200 Kms. Avg.distance covered; Safety on road of prime

importance

Wide no. of transporters with drivers / helpers, notnecessarily dedicated



Ascertain the condition of the road prior to loading ofmaterial. Plan the travel route before starting the journey. It is important to find out in advance whether the road

through which chlorine has to be transported is closedor has any diversions.

Shortcuts should never be preferred. Follow the speed limits. Never consume intoxicating substances during driving. Always carry the fitness certificate of the vehicle while

transporting chlorine from supplier to consumer or vice-versa.

The validity of such fitness certificate is only for twoyears so it is essential to renew the same after everytwo years.

Always keep the Vehicle License and Fitness certificate

in the vehicle transporting Chlorine.

SAFETY PRACTICES OF

TRANSPORTATION- DRIVERS



Vehicles should be fit and road worthy for transportation ofchlorine.

Ensure that the brakes of the vehicle are working properly sothat the vehicle can be stopped any time on the route.

The drivers transporting chlorine should be trained to verifythe labels pasted/marked on the truck is as per thedangerous & hazardous nature of the goods beingtransported and is also marked with appropriate color codes.

Necessary first aid kit, safety kit, tool box should always beavailable with the driver in the truck itself.

Drivers are to be provided with written instructions regardinghazardous nature of chlorine being transported by him andalso the precaution to be taken during transportation.

It is necessary to install a spark arrestor device in thevehicle.

Emergency Panel for information-chemical/class hazardouspublic control should be pasted on 3 sides of the truck





SAFETY PRACTICES OF TRANSPORTATION-

MANUFACTURER

Loading of the chlorine tonners should be done under the supervision of experienced and trained persons.

Filled chlorine tonners are required to be placedhorizontally in a single layer with valves of all tonners

facing in the same direction. In order to prevent the tonner from falling duringtransportation, they should be supported with woodenwedges.

The loading of all the tonners in the truck/vehicleshould always be within its loading capacity. It shouldalso be noted that no tonners or any part of it shoulddangle out of the truck.

It should be ensured that neither any other goodsshould be loaded in the truck along with chlorine nor any passenger should be transported in the truck

loaded with chlorine tonner.



The vehicle on route if required to be parked then itshould be parked in an open the place should beshadowed, windy and open area. Vehicle should not be

parked under direct sunlight. Ascertain in advance, availability of safe & proper

parking places en route or at customers place so that incase of emergency the vehicle can be park in such safeplace.

Driver remembers the preventive measures required tobe taken during adverse weather condition.

After the chlorine tonner reaches at the customer end,always use mechanical or electrical devices forunloading the tonner. Magnet or Sling should never beused for unloading the same.

Tonners should never be thrown directly on the floor. Even through all safety measures taken and all

preparation had to be done for safe journey, yet it isalso essential to remain prepared to face anyemergency situation.



SAFETY PRACTICES OF

TRANSPORTATION- TRANSPORTER

Transporter must be fully acquainted with nature of Cargo, its

General Properties, transportation, Safety Kits, emergency Kits, etc.

before accepting the Tonner from supplier.

It is preferable to use the Tucks open able from sides to enable easy

approach to attend any leakage. Transporter must carry Gas Mask, Emergency Kits and Fire

Extinguishers while transporting Chlorine Cylinders

Never transport Cylinder in Multi Layers on the Truck, Lay them in a

Single Layer Only. Do not load Truck with any other cargo.

All containers must have valve caps and hoods fitted on them during

transportation.

Cylinders / Tonners should not project outside the frame of the

vehicle.

No passenger must be taken on the way and allowed to travel in the

truck carrying liquid chlorine.



The driver must keep in mind that he is carrying Hazardous

Cargo and should drive cautiously. He should avoid over

speeding, sharp turns, and overtaking.

Use wooden wedges to support the toners firmly, to ensure

that there is no free movement of tonners, if the journey is

through such a rout, the container should be securely tied to

truck with a strong rope, so as to prevent rolling.

Tonner should be layed in horizontal position with valve in aVertical Plane and small Cylinder in Vertical Position with

Valves Upside.

The Trucks should not to be parked in direct sunlight or near

the Fire, & should never be parked near residential/ crowded

locality. Never allow water to come in contact with the Tonners.

Always keep a bottle of dilute Ammonia in the cabin. In case

of smell or doubt of chlorine leakage, wet a cloth tied on

wooden baton with Ammonia solution an take it near each

end of the container, white fumes indicates Chlorine leak.



In case of Chlorine leakage from Tonner Valve, bring the leaky valve

in upside position by rolling Tonner so that any Leaky points will

come on top, thus only gas will come out.

Never drop/throw the containers from the vehicle. Slightly roll it on

a slope. Avoid striking containers against any hard object.

No transshipment should be done unless required in emergencies

such as vehicle breakdown.

In case of leakage of the chlorine tonners during transportation,

driver should not park the vehicle in any residential area. The driver

should park the vehicle in the open area at an isolated place.

Contact the local police station, transporter or manufacturer on

phone. If the driver is trained, than he can identify the leaking

tonner & plug the leak by placing the safety kit properly.

Leaking tonner should not be transported

Avoid gathering of crowds near the leaking truck.

Avoid spraying water over the leak.



TRANSPORT PRACTICES IN OTHER

COUNTRIES

Vehicle Inspection Check List

Support basis along the routes to be covered.

Tracking of Vehicles by Satellite

Emergency Response Plan

Partnership with Emergency Support Companies Partnership among Producers

Drivers training

Emergency Equipment (Respiratory Protection, Emergency Kit)

Emergency Datasheet

MSDS Material Safety Datasheet

Greater Supervision of Vehicles carrying Hazardous Substances

Manufacturers Companies & Transportation Companies to adopt

Responsible Care

More restrictive legislation for chemicals transportation by

highways

Monitoring, Reporting and Proper Actions for incidents prevention



Straps & logistic rail for securing cylinders



Load bars & logistic rail for securing cylinders



Ground level loading & unloading cylinders



Ton container blocking



Front bulkhead reinfor cement for ton containers



Incident of Chlorine Gas Leakage from Tonner during

Transportation

On 5th September 2010 at

Village Chhattar on Rajkot-Morbi Highway (Gujarat)

Incident

A truck (GJ15Z1981) carrying 19 filled Chlorine tonners was on way to oneof the consumer in Gandhidham (Gujarat), got toppled down on the side lineof main highway road in the early hrs at about 12:15 a.m. of 5th September,2010.

Due to sudden hitting impact of tonners, one side of the truck broke downand 11 tonners slipped out of the truck, on the muddy surface.

One tonner (No. 0892 tested on Oct.2009) valve got damaged and Chlorineleakage started. Approx. 59 minor affected people were taken to near byhospital and discharged after First Aid.

Potential Root Cause:

All of sudden one unknown four wheeler comes in front of truck from wrongside and driver lost his control in view of avoiding head on collision.



Control & Rescue Operation

On receipt of information at midnight, emergency control

team from the supplier¶s factory along with marketing

person rushed to the incident site. Mean while two

rescue teams from Rajkot and Morbi fire brigade also

rushed to the site and undertook the rescue operations.

Consumer Rescue Team also reached to the incident

site for taking control of the situation.

The leaky cylinder was brought back to the supplier premises after fixing valve hood over leaky valve.

Remaining 18 cylinders were sent to the consumer site

after thorough checking and ensuring that they are fit for

transportation and use.



Lesson Learnt from the Incident

Counseling and more vigorous refresher trainings to be

organized for chlorine truck drivers so that they should be more

vigilant during driving on main high ways.

A GPS tracking device shall be installed on trucks to determine

the precise location of a vehicle and to record the position of

the vehicle at regular intervals.

Use of strong belts with tension adjusting device shall be made

compulsory in place of conventional ropes.

Trucks shall have the large space on the sides so that in caseof any leakage in the tonners during transportation can be

attended on truck itself.

A System to verify the suitability of the trucks for transportation

of Chlorine tonners shall have to be devised and followed.



CONCLUSION

Chlorine can be handled safely ---Through the close co- ordination of

Manufacturer, Transporter , Customers

AndThrough the sincere approach of personsassociated with the handling of chlorine.

Under these conditions chlorine can be atrue friend & real gift to mankind.

Documents

R-1Copy of Guidelines for Safe Transportation of Chlorine Tonners