DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV.

DATE 07/01/2014 PAGE 1 of 15

WORK INSCTRUCION
Department:



TITLE: Post-Wise Hazards & Risk Amassment


1.0 PURPOSE :
The purpose of this section is to familiarize the operator with some potential hazards in the
ammonia Plant and the equipment provided to control the hazards. The use of safe procedures
and the proper safety equipment is a help in conducting our business, not a hindrance it is
essential that the operator develop positive safety attitude. This will occur only when he firmly
believe that the safe way is the only way he can properly do his job. The operator is not only
responsible for his own safety he has a responsibility to conduct himself in such a manner so as
not to jeopardize the safety of his fellow employees. The Operator is the proprietor of the plant.
He is operating and as such has the prime responsibility for the safety of all who enter his work
area.

2.0 SCOPE:
Following procedure will help for the hazards identification and their risk assessment at ammonia plat post-
wise.


3.0 DE-ARATOR AREA HAZARDS

Sr.No Hazards Involved Description
1 Chemicals
Anti corrosion, oxygen removal and Ph control chemicals are
being used in BFW and steam system. The exposure can cause
serious health problems with eyes or skin. Use proper personal
protective while working in the BFW and steam systems. In
case of a contact with the chemicals wash with plenty of water
and sort medical help.
Hydrazine 35%
W/W (N2H4)
Safety Profile: It is colorless liquid, causes eye burns, and may cause blindness.
Causes skin and respiratory tract irritation
Precautions: Handle only when wearing complete protective equipment, including
chemical suit, rubber gloves, boots, and goggles. Avoid accidental contact with skin
and eyes. Do not breathe vapor .Use only in well ventilated areas where exposure
level is at or below 0.1 ppm.
First Aid: In case of skin and eye contact- immediately wash with clean water for 15
min. If ingested wash out mouth thoroughly with water and continue to drink
plenty of water. If inhaled remove to fresh air. Refer to FFCL medical Center.




ROUTE PREPARED BY REVIEWED BY APROVED BY REFERENCE
Name SAQIB RAOUF
QMS : 5.5.1
HSE : 4.4.1
Date 28-08-14




Desig./Sign.
DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 2 of 15



Tri-sodium
Phosphate
(Na3PO4)
Safety Profile: it is odorless non-combustible powder. Inhalation, Eye and Skin
Contact may cause irritation and discomfort, Avoid breathing. Overexposure can
cause lung disease or asthma.
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Avoid handling method creating excessive
dust. Use hygienic methods, dont eat and drink while handling this compound.
First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean
water for minimum 15 minutes. Prompt irrigation of the eyes with clean water
prevents serious eye injury. Skin Contact quickly wash with plenty of water with
soap. Remove contaminant clothing. Inhalation- If dust is inhaled, Move to fresh air.

Ammoniacal
water
Safety Profile: it is solution of ammonia, in case of contact can cause irritation to
skin, eyes and upper respiratory tract; headache, nausea. Inhalation of vapors may be
fatal by causing glottis to spasm and suffocation. Can have delayed effect after
moderate exposure.
Precautions: In case of Eye contact-hold eyelids open and immediately wash eyes
with clean water for minimum 15 minutes. Prompt irrigation of the eyes with clean
water prevents serious eye injury. In case of Skin Contact quickly wash with plenty
of water. Do not apply any ointments.
First Aid: If in contact with clothing, immediately remove contaminated clothing and
get under shower or any other source of water. Take care of attached skin (if any)
due to cryogenic action of ammonia.
2 Steam
Area comprises a small network of steam. Steam is used for
the operation of different steam turbines. There are many
steam headers of different pressures. Steam system operates
at every high temperature. There is a risk of burns if exposed
to high temperature and high pressure steam. Area operators
are advised to use special precautions and protective against
this hazard. Do not touch the naked steam piping. Use PPE
while taking samples and operating or attending maintenance
activities at steam
3 Electricity
An electrical work permit to be obtained before any work is to
be performed on any electrical circuit. The electrical power
source should be turned off and lock out tag out procedure to
be strictly followed. Stay in contact with your shift supervisor
and Shift Co-coordinator to ensure that correct power source
or breaker has been turned off / disconnected / locked an
properly tagged. Work permit procedure and lock out tag out
procedures to be followed strictly. An incident will be recorded
if electrical job found in progress without wok permit, proper
authorization and proper isolation.
4 Nitrogen
Nitrogen is inert gas used as sealing media for condensing
turbines especially in this area .It is also used for purging
equipment. It is not poisonous or flammable but care must be
exercised when working on equipment that is being purged.
Adequate ventilation must be provided or appropriate
breathing devices worn. To breath an atmosphere high in
nitrogen could result in suffocation and death. Before entering
vessels that have been purged with nitrogen a check must be
made for proper oxygen concentration and an entry tape must
be cleared.

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4.0 REFORMING AREA HAZARDS

Sr.No Hazards Involved Description
1 Explosive Mixture
Process and equipment in the area contain explosive gases
Hydrogen, Methane, Ethane and ammonia. Explosive Mixtures
can exist when ever air or oxygen is in present in the system.
During startup purging procedures must be followed closely.
All equipment must be air free before hydrocarbons can be
allowed into the system. Follow the proper purging procedures
for commissioning of the system with Hydrocarbons.
Auto Ignition
Temp=538 C

LEL=5%
UEL=15%

METHANE (CH4)
Safety Profile: it is Colorless, odor less and tasteless gas. It is the major constituent
of natural gas. Highly flammable and explosive gas which forms inimitable mixtures
with air. It is a buoyant gas which may collect under roofs or ceilings forming
pockets of explosive gaseous mixture. Not toxic but a simple asphyxiate.
Precautions: Before any work is performed on vessels, piping or equipment that
have or could have contained methane in any concentration, they must be
thoroughly purged with nitrogen and then carefully checked with an explosivity
meter for the presence of flammable gas.
First Aid: A person asphyxiated by the Methane Should be removed to fresh air
immediately and kept warm and quiet until medical assistance can be obtained. If
the victim has stopped breathing, artificial respiration must be given immediately.
Auto Ignition
Temp=500 C

LEL=4%
UEL=75%


HYDROGEN




Safety Profile: it is Colorless, odor less and tasteless gas. Highly flammable and
explosive gas which forms inimitable mixtures with air. It is a buoyant gas which may
collect under roofs or ceilings forming pockets of explosive gaseous mixture. Not
toxic but a simple asphyxiate.
Precautions: Before any work is performed on vessels, piping or equipment that
have or could have contained hydrogen in any concentration, they must be
thoroughly purged with nitrogen and then carefully checked with an explosi-meter
for the presence of flammable gas. If a hydrogen rich gas leaks should develop from
equipment containing the gas at high temperature (e.g. primary reformer out let
pigtail) immediately apply steam directly on the source of the leak to stop or
prevent a fire. NEVER USE WATER
First Aid: A person asphyxiated by the Hydrogen Should be removed to fresh air
immediately and kept warm and quiet until medical assistance can be obtained. If
the victim has stopped breathing, artificial respiration must be given immediately.
Auto Ignition
Temp=609 C

LEL=12.5%
UEL=74.8%

CARBOB
MONOOXIDE
(CO)

IDLH=1200ppm
TWA=25ppm
Safety Profile: it is Colorless, odor less and Flammable gas. Mildly toxic by
inhalation. Systematic effects on humans by inhalation. It can cause asphyxiation by
preventing hemoglobin from binding with oxygen. Acute cases of poisoning resulting
from brief exposure to high concentration seldom result in any permanent disability
if recovery takes place in time.
Precautions: Use forced ventilation to dilute concentrations around process
leaks.Use self contained breathing apparatus in concentrations above 50 ppm. Do
not work in confided spaces with combustion engines running unless there is
adequate ventilation.
First Aid: A person overcome by or exhibiting signs of carbon monoxide poisoning
must be removed to fresh air immediately and kept warm. Administer oxygen if
necessary until medical assistance can be obtained.





DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 4 of 15



2 Steam
Area comprises a large network of steam generation and
steam consumer vessels and piping steam is being produced
and superheated in this area and is consumed for reforming
process Steam is also used for the operation of different steam
turbines. There are many steam headers of different pressures.
Steam system operates at every high temperature. There is a
risk of burns if exposed to high temperature and high pressure
steam. Area operators are advised to use special precautions
and protective against this hazard Do not touch the naked
steam piping Use PPE while taking samples and operating or
attending maintenance activities at steam.
3 Nitrogen
Nitrogen is inert gas used for purging of equipment. It is not
poisonous or flammable but care must be exercised when
working on equipment that is being purged. Adequate
ventilation must be provided or appropriate breathing devices
worn. To breath an atmosphere high in nitrogen could result in
suffocation and death. Before entering vessels that have been
purged with nitrogen a check must be made for proper oxygen
concentration and an entry tape must be cleared.
4 Primary Reformer
Primary Reformer and surrounding areas contain serious fire
hazards. Draft is controlled in primary reformer to keep flames
confined inside the fire box, Loss of draft or a positive pressure
may result in a back fire and travel of flames to outwards from
openings causing serious burns an injury to personal working
in the area, Personal working in the area should be careful
about the hazard check draft and use proper personal
protective while climbing the primary reformer decks
5 BFW
Reforming area has steam generation network and Boiler feed
water is used to produce steam, BFW being used is of high
temperature. Any person exposed to high temperature BFW
will get serious burns. Proper Personal protective must be used
while working at steam generators and BFW circuits.
6 Leaks
Hydrogen and ammonia leaks can frequently be controlled
sufficiently to enable operators to shut off control valves, by
directing water hose stream on the leak. In severe Ammonia
leaks large volumes of water are needed. Warn all employees
in the area in which the leaks occur and in the surrounding
area which may be affected. Remove or control the possible
sources of ignition. In cases where leaking point cannot be
isolated use large volumes of water played directly on the
leaks and maintain contact unit the contents have been
discharged and the vessel or line is depressurized.
7 Mercury
Mercury (from thermometers, Manometers etc) should never
be allowed to come in contact with ammonia due to the
formation of explosive compounds. Get the area cleaned
immediately in case of a mercury spill.





DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 5 of 15



8 Electricity
An electrical work permit to be obtained before any work is to
be performed on any electrical circuit. The electrical power
source should be turned off and lock out tag out procedure to
be strictly followed Stay in contact with your shift supervisor
and Shift Co-coordinator to ensure that Correct power source
or breaker has been turned off / disconnected / locked an
properly tagged. Work permit procedure and lock out tag out
procedures to be followed strictly. An incident will be recorded
if electrical job found in progress without wok permit, proper
authorization and proper isolation.
9 Catalysts
Several catalysts are used in the area in Primary reformer,
secondary reformer, desulfurizer pre-reformer, HTSC and LTSC.
Dust from these catalysts is a serious health hazard Special
care must be taken and proper personal protectives must be
used while working with the catalysts. Catalysts are Pyrophoric
also such materials will burn spontaneously in the presence of
oxygen. Catalysts in the vessels are in reduced state and when
they are exposed to oxygen a violent reaction occurs which is
exothermic and produces heat. A fire could result causing
serious injury to personal working in the area and damage to
the equipment special precautions must be taken while
removing any catalyst from vessel or opening up nay catalyst
vessel. There might be migration of catalyst dust to the
catalyst vessel downstream equipment and piping Any such
build in the downstream circuits should also be watched while
opening up to atmosphere for repairs or inspection.
Hydro
Processing
Catalyst
(TK-261)
Safety Profile: it is odor less Non-combustible solid. Product Ingredients are NiO (1-
3%), MoO3 (7-13%) and Al2O3 (80-90%). insoluble in water however leaching may
occurs. Inhalation, Eye and Skin Contact may cause irritation and discomfort. Product
contains Nickel oxide which is carcinogenic and it has long term adverse effects on
aquatic environment.
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Avoid handling method creating excessive
dust. Use hygienic methods, dont eat and drink while handling this compound.
First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean
water for minimum 15 minutes. Prompt irrigation of the eyes with clean water
prevents serious eye injury. In case of Skin Contact quickly wash with plenty of water
with soap. Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case
of ingestion seek medical attention
Sulphur
Absorption
Catalyst
(HTZ-5)
Safety Profile: it is odor less non-combustible solid. Product Ingredients are 99-
100% ZnO. Insoluble in water however leaching may occurs. Inhalation, Eye and Skin
Contact may cause irritation and discomfort. It has long term adverse effects on
aquatic environment.
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Avoid handling method creating excessive
dust. Use hygienic methods, dont eat and drink while handling this compound.
First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean
water for minimum 15 minutes. Prompt irrigation of the eyes with clean water
prevents serious eye injury. In case of Skin Contact quickly wash with plenty of water
with soap. Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case
of ingestion seek medical attention

DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 6 of 15



Sulphur
Absorption
Catalyst
(ST-101)
Safety Profile: it is odor less non-combustible solid. Product Ingredients are 99-
100% ZnO. Insoluble in water however leaching may occurs. Inhalation, Eye and Skin
Contact may cause irritation and discomfort. Product contains Zinc oxide which is
carcinogenic and it has long term adverse effects on aquatic environment.
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Avoid handling method creating excessive
dust. Use hygienic methods, dont eat and drink while handling this compound.
First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean
water for minimum 15 minutes. Prompt irrigation of the eyes with clean water
prevents serious eye injury. In case of Skin Contact quickly wash with plenty of water
with soap. Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case
of ingestion seek medical attention
Steam
Reforming
Catalyst
(R-67-7H)
Safety Profile: it is odor less non-combustible solid. Product Ingredients are NiO
(15-20%), MgO (20-25%) and Al2O3 (55-60%).Insoluble in water however leaching
may occurs. Inhalation, Eye and Skin Contact may cause irritation and discomfort.
Nickel and Nickel Oxide compounds are carcinogenic in nature. Product contains
Nickel Oxide which is very toxic and has long term adverse effects on aquatic
environment.
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Avoid handling method creating excessive
dust. Use hygienic methods, dont eat and drink while handling this compound.
First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean
water for minimum 15 minutes. Prompt irrigation of the eyes with clean water
prevents serious eye injury. In case of Skin Contact quickly wash with plenty of water
with soap. Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case
of ingestion seek medical attention
Steam
Reforming
Catalyst
(RKS-2)
Safety Profile: it is odor less non-combustible solid. Product Ingredients are NiO (7-
13%), MgO (25-30%) and Al2O3 (60-70%).Insoluble in water however leaching may
occurs. Inhalation, Eye and Skin Contact may cause irritation and discomfort. Nickel
and Nickel Oxide compounds are carcinogenic in nature. Product contains Nickel
Oxide which is very toxic and has long term adverse effects on aquatic environment.
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Avoid handling method creating excessive
dust. Use hygienic methods, dont eat and drink while handling this compound.
First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean
water for minimum 15 minutes. Prompt irrigation of the eyes with clean water
prevents serious eye injury. In case of Skin Contact quickly wash with plenty of water
with soap. Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case
of ingestion seek medical attention
High
Temperature
Shift Catalyst
(SK-201-2)
Safety Profile: it is odor less non-combustible solid. Product Ingredients are Fe2O3
(80-90%), Cr2O3 (8-13%) and CuO (1-2%).Insoluble in water however leaching may
occurs. Inhalation, Eye and Skin Contact may cause irritation and discomfort. Nickel
and Nickel Oxide compounds are carcinogenic in nature. Product contains Nickel
Oxide which is very toxic and has long term adverse effects on aquatic environment.
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Avoid handling method creating excessive
dust. Use hygienic methods, dont eat and drink while handling this compound.
First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean
water for minimum 15 minutes. Prompt irrigation of the eyes with clean water
prevents serious eye injury. In case of Skin Contact quickly wash with plenty of water
with soap. Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case
of ingestion seek medical attention
DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 7 of 15





Low
Temperature
Shift Catalyst
(LSK)
Safety Profile: it is odor less non-combustible solid. Product Ingredients are Cr2O3
(40-50%), CuO (15-20%) , ZnO (25-35%).Insoluble in water however leaching may
occurs. Inhalation, Eye and Skin Contact may cause irritation and discomfort. Nickel
and Nickel Oxide compounds are carcinogenic in nature. Product contains Nickel
Oxide which is very toxic and has long term adverse effects on aquatic environment.
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Avoid handling method creating excessive
dust. Use hygienic methods, dont eat and drink while handling this compound.
First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean
water for minimum 15 minutes. Prompt irrigation of the eyes with clean water
prevents serious eye injury. In case of Skin Contact quickly wash with plenty of water
with soap. Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case
of ingestion seek medical attention


5.0 CATACARB AREA HAZARDS

Sr.No Hazards Involved Description
1 Catacarb Solution
Catacarb solution is mixture of different chemicals which is
used to remove carbon di-oxide from the process gas.It is basic
and corrosive in nature. Use proper PPES while handling it.
POTASSIUM
CARBONATE
(K2CO3)
Safety Profile: Potassium carbonate is white deliquescent granular or translucent
powder with alkaline. It is non flammable, Irritating to eyes and respiratory system.
Repeated or prolonged skin contact may cause irritation Taste.
Precautions: Avoid skin contact- use rubber gloves, chemical splash suit. Avoid eye
contact use goggles. Avoid inhalation use dust mask.
First Aid: In case of skin contact- immediately brush off any powder and wash with
water. In case of Eye Contact wash with plenty of water. In case of Inhalation
blow nose clean and wash nostrils.
CATACARB 400
Safety Profile: it is proprietary mixture (organic) used in Catacarb.it Can explode if
heated under confinement. Hot organic Chemical vapors may spontaneously ignite
or explode when mixed with air, even at temperature below their published auto
ignition temperature. Irritating to eyes and respiratory system. Repeated or
prolonged skin contact may cause irritation.
Precautions: Wear PPEs and portative equipments, handling in adequate
ventilation; dont breathe vapor mist or dust. Do not get in eyes on skin or clothing.
Dont swallow. Avoid contact with skin, eyes and clothing. After handling this product
wash hands before eating, drinking or smoking. if contact occurs, remove
contaminated clothing
First Aid: In case of skin contact- Immediately flush skin with plenty of water for at
least 15 min while removing contaminated clothing and shoes. In case of Eye Contact
Immediately flush eyes with water for 15 minutes while holding eyelids apart to
ensure flushing of entire surface. In case of Inhalation Moved to fresh air. If not
breathing give artificial respiration. Ingestion ingestion may cause pain, severe
irritation, burns, nausea, vomiting, diarrhea, drowsiness, internal bleeding, coma and
even death.



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Vanadium Pent
oxide (V2O5)
Safety Profile: It is non combustible, odorless orange powder. Inhalation, Eye
and Skin Contact may cause irritation and discomfort, Avoid breathing dust.
Overexposure can cause lung disease or asthma, headache and dry cough
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Use rubber gloves, chemical resistant suit and
SCBA. Avoid handling method creating excessive dust. Use hygienic methods, dont
eat and drink while handling this compound.
First Aid: In case of Eye contact-hold eyelids open and immediately wash eyes with
clean water for minimum 15 minutes. Prompt irrigation of the eyes with clean water
prevents serious eye injury. In case of Skin Contact quickly wash with plenty of
warm water. Remove contaminant clothing. Inhalation- If dust is inhaled, Move to
fresh air and consult with FFL Medical Centre. Ingestion In case of ingestion seek
medical attention
CATACARB De-
foamer WBU

Safety Profile: it is proprietary mixture (organic) used in Catacarb as Anti-Foamig
agent. Use water to cool containers exposed to fire. a direct stream of water cause
foaming. Irritating to eyes and respiratory system. Repeated or prolonged skin
contact may cause irritation.
Precautions: Wear PPEs and portative equipments, handling in adequate
ventilation; wash thoroughly after handling. Do not get in eye skin contact. Avoid
prolonged or repeated skin contact. Dont swallow. Keep heat, fire and spark away.
For industrial use only. Emptied contains product residues (vapor, liquid) all labeled
hazard precautions must be observed. Avoid contact with skin, eyes and clothing.
After handling this product wash hands before eating, drinking or smoking. If contact
occurs, remove contaminated clothing.
First Aid: In case of skin contact- Immediately flush skin with plenty of water for at
least 15 min while removing contaminated clothing and shoes. In case of Eye Contact
immediately flush eyes with water for 15 minutes while holding eyelids apart to
ensure flushing of entire surface. In case of Inhalation Moved to fresh air. If not
breathing give artificial respiration. Ingestion If swallowed dont induce vomiting.
Rinse mouth with water. Dilute stomach content by drinking water. Never gave
anything by mouth to unconscious person.
2 Steam
Area comprises a network of steam and steam consumer
vessels. Steam is also used for the operation of different steam
turbines. There are many steam headers of different pressures.
Steam system operates at every high temperature. There is a
risk of burns if exposed to high temperature and high pressure
steam. Area operators are advised to use special precautions
and protective against this hazard. Do not touch the naked
steam piping. Use PPE while taking samples and operating or
attending maintenance activities at steam.
3 Electricity
An electrical work permit to be obtained before any work is to
be performed on any electrical circuit. The electrical power
source should be turned off and lock out tag out procedure to
be strictly followed Stay in contact with your shift supervisor
and Shift Co-coordinator to ensure that Correct power source
or breaker has been turned off / disconnected / locked an
properly tagged. Work permit procedure and lock out tag out
procedures to be followed strictly. An incident will be recorded
if electrical job found in progress without wok permit, proper
authorization and proper isolation.


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4 Nitrogen
Nitrogen is inert gas used for purging equipment It is not
poisonous or flammable but care must be exercised when
working on equipment that is being purged. Adequate
ventilation must be provided or appropriate breathing devices
worn. To breath an atmosphere high in nitrogen could result in
suffocation and death. Before entering vessels that have been
purged with nitrogen a check must be made for proper oxygen
concentration and an entry tape must be cleared.
5 Hydrogen
The area contains huge quantities of Hydrogen. Hydrogen is a
highly flammable gas and it is present at high pressure in the
Unit. Hydrogen leaks are not easily seen and care must be
taken when working around equipment that contains
hydrogen. Hydrogen has the ability to auto ignite so an outside
ignition source is not necessary. Burning hydrogen is very
difficult to see. If a leak is suspected the operator must move
carefully so as not to come in contact with it. The leak and
explosively testing should be carried out regularly by the
operator to avoid a potential fire hazard in the area.
Explosively should be checked at and around the work place
before allowing any hot work. Steam should be applied
immediately at the point where leak is suspected to dilute the
explosive mixture. If such detected inform shift supervisor and
shift coordinator immediately.
6 Carbon Di-oxide
Safety Profile: it is Colorless, odor less and non flammable gas. A
simple asphyxiate gas. As an inert gas, it has no specific inherent
dangerous properties. Gases of this type have no specific toxicity
effect, but they act by excluding oxygen form the lungs.
Precautions: Never enter a confined space / vessel without first
satisfying all the requirements of the confined space entry
certificate. Use self contained breathing apparatus when entering
vessels that contain high concentration of CO2.
First Aid: Inhalation a victim overcome by carbon dioxide must be
removed to fresh air immediately and referred to the FFCL medical
centre. If the victims breathing has stopped begin artificial
respiration.
7
NICKEL CARBONYAL
(Ni(CO)4

Safety Profile: it is Colorless, potentially fatal if inhaled volatile
liquid. Severe fire and explosion hazard. Vapors are heavier than air
and may ignite at distance form source and flash back. Vapor and air
mixture are explosive.
First Aid: In case of eye contact-hold eyelids open and immediately
wash eyes with clean water for minimum 15 minutes. In case of skin
Contact quickly wash with soap and plenty of water for 15
minutes. Remove contaminated clothing. If inhaled; immediately
move from contaminated area; give artificial breathing if not
breathing. If Ingested: move to fresh air, if vomiting keep head
lower than hips to prevent aspiration. If person is unconscious turn
head to side and Immediately Refer to FFCL medical Center.

8 Catalysts
Methanation catalyst is used in methanator to increase the
rate of methanation of CO and CO2



DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 10 of 15



Methanation
Catalyst (PK-7R)

Safety Profile: it is odor less Non-combustible solid. Product Ingredients are Ni (25-
30%), NiO (1-5%) and Al2O3 (60-70%). Insoluble in water however leaching may
occurs. Inhalation, Eye and Skin Contact may cause irritation and discomfort. Product
contains Nickel oxide which is carcinogenic and it has long term adverse effects on
aquatic environment.
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Avoid handling method creating excessive
dust. Use hygienic methods, dont eat and drink while handling this compound.
First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean
water for minimum 15 minutes. Prompt irrigation of the eyes with clean water
prevents serious eye injury. In case of Skin Contact quickly wash with plenty of water
with soap. Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case
of ingestion seek medical attention


6.0 SYNTHESIS AREA HAZARDS

Sr.No Hazards Involved Description
1 Hydrogen
The area contains huge quantities of Hydrogen. Hydrogen is a
highly flammable gas and it is present at high pressure in the
Unit. Hydrogen leaks are not easily seen and care must be
taken when working around equipment that contains
hydrogen. Hydrogen has the ability to auto ignite so an outside
ignition source is not necessary. Burning hydrogen is very
difficult to see. If a leak is suspected the operator must move
carefully so as not to come in contact with it. The leak and
explosively testing should be carried out regularly by the
operator to avoid a potential fire hazard in the area.
Explosively should be checked at and around the work place
before allowing any hot work. Steam should be applied
immediately at the point where leak is suspected to dilute the
explosive mixture. If such detected inform shift supervisor and
shift coordinator immediately.
2 Explosive Mixture
Process and equipment in the area contain explosive gases
Hydrogen Methane and ammonia. Explosive Mixtures can exist
when ever air or oxygen is in present in the system. During
startup purging procedures must be followed closely. All
equipment must be air free before hydrocarbons can be
allowed into the system. Follow the proper purging procedures
for commissioning of the system with Hydrocarbons.
3 Nitrogen
Nitrogen is inert gas used for purging equipment It is not
poisonous or flammable but care must be exercised when
working on equipment that is being purged. Adequate
ventilation must be provided or appropriate breathing devices
worn. To breath an atmosphere high in nitrogen could result in
suffocation and death. Before entering vessels that have been
purged with nitrogen a check must be made for proper oxygen
concentration and an entry tape must be cleared.

DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 11 of 15




4 Steam
Area comprises a large network of steam generation and
steam consumer vessels and piping steam is being produced
and superheated in this area and is consumed for reforming
process Steam is also used for the operation of different steam
turbines. There are many steam headers of different pressures.
Steam system operates at every high temperature. There is a
risk of burns if exposed to high temperature and high pressure
steam. Area operators are advised to use special precautions
and protective against this hazard Do not touch the naked
steam piping Use PPE while taking samples and operating or
attending maintenance activities at steam.
5 Leaks
Ammonia synthesized in synthesis section as well as anhydrous
ammonia is used as a refrigerant in refrigeration section.
Ammonia is a toxic gas under ambient conditions. Many parts
of a refrigeration section contain ammonia liquefied under
pressure. Releases of ammonia have the potential for harmful
effects on workers and the public. If the ammonia is under
pressure, risk of exposure increases since larger quantities of
the refrigerant have the potential for rapid release into the air.
Also, some explosions have been attributed to releases of
ammonia contaminated with lubricating oil.
6 Ammonia
Safety Profile: It is Colorless, combustible gas (when escaping from
a pressurized system may appear as white plume).Extremely
pungent odor, liquefied by compression. Very soluble in water. In
case of contact can cause irritation to skin, eyes and upper
respiratory tract; headache, nausea. Inhalation of vapors may be
fatal by causing glottis to spasm and suffocation. Can have delayed
effect after moderate exposure.
Precautions: In case of Eye contact-hold eyelids open and
immediately wash eyes with clean water for minimum 15 minutes.
Prompt irrigation of the eyes with clean water prevents serious eye
injury. In case of Skin Contact quickly wash with plenty of water.
Do not apply any ointments.
First Aid: If in contact with clothing, immediately remove
contaminated clothing and get under shower or any other source of
water. Take care of attached skin (if any) due to cryogenic action of
ammonia.

7
Perlite
It is cold insulation material used in cold box.
Safety Profile: It is white to off white granules, no odor. Visual only
(dust), No gas, vapors, or mist emitted. Perlite is a naturally
occurring mineral. In itself it is not a toxic mineral. This material
presents little threat for human health provided that the standards
of industrial hygiene.
Precautions: The use of engineering measure (e.g. local dust
extraction) is recommended to provide effective dust control in
order to ensure compliance with the current Occupational Exposure
Limits.
First Aid: The product is not primary irritant but eye contact may
cause irritation due to abrasion so rinse with plenty of water for 15
minutes. The product is not primary irritant but persistent skin
contact may cause irritation due to abrasion. Excessive inhalation of
product dust may give rise to temporary irritation of the respiratory
DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 12 of 15

tract, as with any powders.

Electricity
An electrical work permit to be obtained before any work is to
be performed on any electrical circuit. The electrical power
source should be turned off and lock out tag out procedure to
be strictly followed Stay in contact with your shift supervisor
and Shift Co-coordinator to ensure that Correct power source
or breaker has been turned off / disconnected / locked an
properly tagged. Work permit procedure and lock out tag out
procedures to be followed strictly. An incident will be recorded
if electrical job found in progress without wok permit, proper
authorization and proper isolation.
9 Catalysts
Catalyst is used in ammonia convertor that increases the ammonia
synthesis reaction.
S-300
Ammonia
Convertor
Catalyst (KM1-
R)

Safety Profile: Faint Smelly Ammonia in Solid, insoluble in water however leaching
may occurs. Product Ingredients are Fe (90-95%), Fe2O3 (1-4%), CaO (1-4%), K2O (0-
1%) and Al2O3 (1-4%).Contact with water may cause self heating and formation of
hydrogen; contact with air above 100C may cause self heating. Inhalation, Eye and Skin
Contact may cause irritation and discomfort. Product is very toxic and has long term
adverse effects on aquatic environment.
Precautions: Dont wash spills into water ways, collect by vacuuming and place in
labeled containers for proper disposal. Avoid handling method creating excessive dust.
Use hygienic methods, dont eat and drink while handling this compound.
First Aid: Eye contact-hold eyelids open and immediately wash eyes with clean water
for minimum 15 minutes. Prompt irrigation of the eyes with clean water prevents
serious eye injury. In case of Skin Contact quickly wash with plenty of water with soap.
Remove contaminant clothing. If dust is inhaled, Move to fresh air. In case of ingestion
seek medical attention



7.0 COMPRESSOR AREA HAZARDS
Sr.No Hazards Involved Description
1 Hydrogen
The area contains huge quantities of Hydrogen. Hydrogen is a
highly flammable gas and it is present at high pressure in the
Unit. Hydrogen leaks are not easily seen and care must be
taken when working around equipment that contains
hydrogen. Hydrogen has the ability to auto ignite so an outside
ignition source is not necessary. Burning hydrogen is very
difficult to see. If a leak is suspected the operator must move
carefully so as not to come in contact with it. The leak and
explosively testing should be carried out regularly by the
operator to avoid a potential fire hazard in the area.
Explosively should be checked at and around the work place
before allowing any hot work. Steam should be applied
immediately at the point where leak is suspected to dilute the
explosive mixture. If such detected inform shift supervisor and
shift coordinator immediately.
2 Mercury
Mercury (from thermometers, Manometers etc ) should never
be allowed to come in contact with ammonia due to the
formation of explosive compounds. Get the area cleaned
immediately in case of a mercury spill.

DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 13 of 15




3 Nitrogen
Nitrogen is inert gas used for purging equipment It is not
poisonous or flammable but care must be exercised when
working on equipment that is being purged. Adequate
ventilation must be provided or appropriate breathing devices
worn. To breath an atmosphere high in nitrogen could result in
suffocation and death. Before entering vessels that have been
purged with nitrogen a check must be made for proper oxygen
concentration and an entry tape must be cleared.
4 Steam
Area comprises a large network of steam. Steam is used for
heating purpose as well as the operation of different steam
turbines. There are many steam headers of different pressures.
Steam system operates at every high temperature. There is a
risk of burns if exposed to high temperature and high pressure
steam. Area operators are advised to use special precautions
and protective against this hazard Do not touch the naked
steam piping Use PPE while taking samples and operating or
attending maintenance activities at steam.
5 Electricity
An electrical work permit to be obtained before any work is to
be performed on any electrical circuit. The electrical power
source should be turned off and lock out tag out procedure to
be strictly followed Stay in contact with your shift supervisor
and Shift Co-coordinator to ensure that Correct power source
or breaker has been turned off / disconnected / locked an
properly tagged. Work permit procedure and lock out tag out
procedures to be followed strictly. An incident will be recorded
if electrical job found in progress without wok permit, proper
authorization and proper isolation.
6 Ammonia
Safety Profile: It is Colorless, combustible gas (when escaping from
a pressurized system may appear as white plume).Extremely
pungent odor, liquefied by compression. Very soluble in water. In
case of contact can cause irritation to skin, eyes and upper
respiratory tract; headache, nausea. Inhalation of vapors may be
fatal by causing glottis to spasm and suffocation. Can have delayed
effect after moderate exposure.
Precautions: In case of Eye contact-hold eyelids open and
immediately wash eyes with clean water for minimum 15 minutes.
Prompt irrigation of the eyes with clean water prevents serious eye
injury. In case of Skin Contact quickly wash with plenty of water.
Do not apply any ointments.
First Aid: If in contact with clothing, immediately remove
contaminated clothing and get under shower or any other source of
water. Take care of attached skin (if any) due to cryogenic action of
ammonia.
7 Explosive Mixture
Process and equipment in the area contain explosive gases
Hydrogen Methane and ammonia. Explosive Mixtures can exist
when ever air or oxygen is in present in the system. During
startup purging procedures must be followed closely. All
equipment must be air free before hydrocarbons can be
allowed into the system.

DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 14 of 15




8.0 STORAGE AREA HAZARDS

Sr.No Hazards Involved Description
1 Ammonia
Safety Profile: It is Colorless, combustible gas (when escaping from
a pressurized system may appear as white plume).Extremely
pungent odor, liquefied by compression. Very soluble in water. In
case of contact can cause irritation to skin, eyes and upper
respiratory tract; headache, nausea. Inhalation of vapors may be
fatal by causing glottis to spasm and suffocation. Can have delayed
effect after moderate exposure.
Precautions: In case of Eye contact-hold eyelids open and
immediately wash eyes with clean water for minimum 15 minutes.
Prompt irrigation of the eyes with clean water prevents serious eye
injury. In case of Skin Contact quickly wash with plenty of water.
Do not apply any ointments.
First Aid: If in contact with clothing, immediately remove
contaminated clothing and get under shower or any other source of
water. Take care of attached skin (if any) due to cryogenic action of
ammonia.
2
Ammonia Storage
Tank
Releases of ammonia have the potential for harmful effects on
workers and the public. A larger quantity of ammonia is stored in
storage tank in this area.
3 Nitrogen
Nitrogen is inert gas used for purging equipment It is not
poisonous or flammable but care must be exercised when
working on equipment that is being purged. Adequate
ventilation must be provided or appropriate breathing devices
worn. To breath an atmosphere high in nitrogen could result in
suffocation and death. Before entering vessels that have been
purged with nitrogen a check must be made for proper oxygen
concentration and an entry tape must be cleared.
4 Electricity
An electrical work permit to be obtained before any work is to
be performed on any electrical circuit. The electrical power
source should be turned off and lock out tag out procedure to
be strictly followed Stay in contact with your shift supervisor
and Shift Co-coordinator to ensure that Correct power source
or breaker has been turned off / disconnected / locked an
properly tagged. Work permit procedure and lock out tag out
procedures to be followed strictly. An incident will be recorded
if electrical job found in progress without wok permit, proper
authorization and proper isolation.
5 Steam
Area comprises a large network of LLP steam. Steam is used for
heating purpose. Steam system operates at every high
temperature. There is a risk of burns if exposed to high
temperature and high pressure steam. Area operators are
advised to use special precautions and protective against this
hazard .Do not touch the naked steam piping Use PPE while
taking samples and operating or attending maintenance
activities at steam.
DOCUMENT CODE SAF-WI-IMS-11 REV. # 00 REV. DATE 07/01/2014 PAGE 15 of 15





6 Mercury
Safety Profile: This product is a clear, volatile, flammable liquid.
Has a slight alcoholic odor. Highly flammable. Vapors may form
explosive mixtures with air. The product causes irritation of eyes,
skin and mucous membranes. Toxic by inhalation, in contact with
skin and if swallowed. Methanol can cause blindness. Causes
headache, drowsiness or other effects to the central nervous
system. Do not allow product to contact skin, eyes and clothing. Do
not breathe vapors.
Precautions: In case of spill or other release use personal
protective equipment. Ensure adequate ventilation. Remove all
sources of ignition. Stop flow of material, if this is without risk.
First Aid: In case of skin contact - Wash off immediately with soap
and plenty of water. Take off contaminated clothing and shoes
immediately. Wash contaminated clothing before re-use. Call a
physician immediately. In case of eye contact Rinse immediately
with plenty of water, also under the eyelids, for at least 15 minutes.
Call a physician immediately. Move to fresh air in case of accidental
inhalation of vapors. If not breathing, give artificial respiration. If
breathing is difficult, give oxygen, provided a qualified operator is
available. Call a physician immediately.



9.0 DISTRIBUTION LIST:


Original : Unit Manger
Copy # 1 : CCR-1
Copy # 2 : Area