Plant Procedure

Chemical Management
ROMCO/OPN/SP-066 Rev.00

Document Approval
Developer S.Sornaboopathi PPE
Reviewer Ali Zikiri OM
Approver Wasim AL-Saeedi PGM
Name Title Date Signature

Contents
1. Purpose.....................................................................................................................................................2
2. Scope........................................................................................................................................................2
Uncontrolled, if printed *Refer latest version in the server *If required, print both the sides*
 Chemical Management
3. Roles and Responsibilities........................................................................................................................3
4. Safety and Health Precautions..................................................................................................................3
5. Environmental Precautions.......................................................................................................................3
6. Equipment/Software.................................................................................................................................3
7. Terminology.............................................................................................................................................4
8. Procedure.................................................................................................................................................4
9. Record......................................................................................................................................................8
10. Legal requirement & References..............................................................................................................8
11. Document Revision History.....................................................................................................................9

1. Purpose

The purpose of this procedure to provide the safe handling and storage of Hazardous and non-hazardous

chemicals to minimize the risks of injury and pollution.

Uncontrolled, if printed *Refer latest version in the server *If required, print both the sides*
ROMCO/OPN/SP-066 Rev: 00 Rev. Date: 11 NOV 2020 Page 2 of 9
 Chemical Management
2. Scope

Scope of the procedure is to increase the knowledge in chemical handling and storage and eliminate the risk &
hazards.
3. Roles and Responsibilities

3.1 Plant General Manager: Responsible for all activities of RABIGH IPP related to Operation, Maintenance
and Administrative departments. Plant General Manager will be responsible for the implementation of
this procedure.

3.2 Operation Manager: Reporting to plant General Manager to all activities in the Operation Department
and maintain the safe work environmental and plant availability as per the contractual requirements.
Operation Manager shall be authorized, with proper approval from the Plant General Manager to make
comments & recommendation for the plant chemical handling procedure. Operation Manager will be
responsible for the implementation of this procedure.

3.3 Chief chemist: Responsible for chemical handling and storage procedure. Evaluating the complete process
of chemical handling system such as material ordering, specification of the chemicals and evaluation the
risk and hazards associated with chemicals. Review the procedure and revise as and when it is required.

3.4 Shift chemist: Responsible for compliance of procedure. Supervise the chemical laborers in receiving,
handling, preparation, and storage of chemicals.
4. Safety and Health Precautions

 Wear helmet, safety shoes, ear plug (muffs) and proper chemical clothes when handling and
operating the chemical equipment.
 Before operating, think carefully about the steps you will take. Inspect the surroundings for any
possible danger and inform your associates of what you plan to do.
 Do not smoke or use a flame in the vicinity of the equipment.
 Maintain housekeeping of the area.

5. Environmental Precautions
 Proper housekeeping must be checked before operating the equipment especially after closing of
work permit.

 Segregate and dispose of all waste to allocated locations, empty drums and cans to be transferred
to the hazardous waste area

6. Equipment/Software
 Forklift for the transport of chemicals
 Acid & Caustic soda unloading pumps
 Portable air transfer pump (optional)
Uncontrolled, if printed *Refer latest version in the server *If required, print both the sides*
ROMCO/OPN/SP-066 Rev: 00 Rev. Date: 11 NOV 2020 Page 3 of 9
 Chemical Management
 Sample bottles suitable for the chemicals
 Laboratory equipment for analysis such as hydrometer, thermometer, etc.
 SAP‐Quality Module (Raw Material Inspection and Usage Decision).

7. Terminology

(MSDS) Material Safety Data Sheets – is a form containing the data regarding the properties
of a chemical or substance. It includes a compilation of information required on the identity of chemicals,
health and physical hazards, exposure limits, and precautions.

(OHS 45001 ISO) is the world's international standard for occupational health and safety, issued to protect
employees and visitors from work-related accidents and diseases, ISO 45001 certification was
developed to mitigate any factors that can cause employees and businesses irreparable harm.

(PPE) Personal Protective Equipment ‐ Means all equipment (including clothing) which is

intended to be worn or used by a person at work and which protects him/her against one or more risks to
his/her health and safety, and any addition or accessory designed to meet that objective.

(QA) Quality Assurance ‐ refers to a program for the systematic monitoring and evaluation
of the various aspects of a project, service, or facility to ensure that standards of quality are being met.

(QC) Quality Control ‐ A system of maintaining standards in manufactured products by

testing a sample of the output against the specification.

(SAP) Systems Applications and Products – an application to provide customers with the ability to interact
with a common corporate database for a comprehensive range of applications.

Carcinogens – any substance that is an agent directly involved in causing cancer.

Mutagens – chemical or physical agents that changes the genetic material, usually DNA of an organism
and this increase the frequency of mutations.

8. Procedure

Process flow chart:

Uncontrolled, if printed *Refer latest version in the server *If required, print both the sides*
ROMCO/OPN/SP-066 Rev: 00 Rev. Date: 11 NOV 2020 Page 4 of 9
 Chemical Management
Creation of
gate pass

Acceptance from the

Main Gate

Clearance from NO
Return to
Security ventor
Entry Permission

YES

Transport of the Bulk

Chemicals inside the plant

Quality Assurance and

Quality Control

YES Results meet NO Rejection/Return

the to vendor
requirements

Unloading to proceed
Storing of the bulk
chemicals

Consumption of chemicals to
Bulk Chemical Bulk Chemicals in drums
all designated areas: R.O
Consumption pails, sacks, canisters, and cylinders
Plant Electro chlorination,
Demi plant, (Boiler), CPP
Hydrochloric Acid and Preparation of Chemicals Plant, Feed Water system,
Caustic Soda Solution from Dilution of Chemicals, Fuel additive system
storage tanks Charging of fuel additive
Disposal of empty
drums, pails,
cylinders, sacks to
OHSA’s accredited
Waste Disposal
contractor

8.1 Creation of Material Gate Pass

Uncontrolled, if printed *Refer latest version in the server *If required, print both the sides*
ROMCO/OPN/SP-066 Rev: 00 Rev. Date: 11 NOV 2020 Page 5 of 9
 Chemical Management
8.1.1 The Laboratory staff should request the gate pass from security department for the bulk chemicals. Line
manager should aware about the chemical delivery and gate pass request. The gate pass should indicate the
following information:
 Name of the bulk chemicals
 Quantity
 Driver’s identity (name, nationality, Iqama no.)
 Registration number of vehicles, plate number

8.1.2 The electronic gate pass will be issued by security officer to main gate.

8.2 Acceptance of Bulk Chemicals from vendor at the main gate

 Before entry the truck the driver should take the safety induction from HSE team
 Entry of the bulk chemical delivery will be permitted upon the clearance from the main gate which is
under the responsibility of Security group personnel at the main gate.

 In case the Security personnel found that delivery of chemicals is not as per the material gate pass
and/or upon checking, the driver does not meet the requirements necessary in the main gate, the
delivery will be not be allowed.

8.3 Transportation inside the Plant

 It is required that tank truck be provided with a document describing the name, components and
grade of the contents, protective equipment, tools and the first aid measures to be taken in case of an
accident.
 If bulk delivery is solution of Hydrochloric acid or caustic soda, the driver must be certain to close the
manholes or valves so that the liquid does not leak.
 The ROMCO personnel, either from the Laboratory or Chemical store will guide the said driver to the
exact receiving site.
 Speed limit must be followed by truck driver not to exceed 20 KM/h and it must be observed inside
the plant. The truck should go directly to store side and must avoid loitering in any areas of the plant.

8.4 Quality Assurance and Quality Control

8.4.1 Bulk Chemicals

 Warehouseman/Storekeeper will check for all the documents upon arrival of the truck at the site.
 Further, he will coordinate and inform the Chief Chemist and/or the chemist upon its
arrival.
 The Chief chemist or the chemist will ascertain that all the pertaining documents with regards to
quality are available; MSDS of the Chemical Laboratory test certificate.
 The truck will be allowed to reach the unloading area if there is already clearance from the store.
 Meanwhile, the warehouse personnel or the storekeeper will post the raw material inspection process
in the SAP system. Once the store personnel posted the documents pertaining to the material, the
inspection lot is created automatically. The quality personnel or the chemist can check the inspection
lots in code QA32 in SAP. Chief Chemist will do the usage decision

Uncontrolled, if printed *Refer latest version in the server *If required, print both the sides*
ROMCO/OPN/SP-066 Rev: 00 Rev. Date: 11 NOV 2020 Page 6 of 9
 Chemical Management
 The shift chemist/chemical handling person should assist with the positioning of the truck on its
loading area. For unloading of liquid chemicals, he should verify the locations of all the fittings and
familiar enough with local panel of the pumps.
 Before unloading and acceptance, the laboratory personnel will collect representative sample. He will
do the physical analysis and perform qualitative test in the laboratory. Sample will be retained for
some duration of time.
 The laboratory personnel, the truck driver will have to follow the safety precautions in the plant till
exit the main gate

Refer to the MSDS for safety and proper handling of the bulk chemicals

 Once the laboratory personnel completed the test, results will be relayed to the chief chemist.
Consequently, results will be recorded and updated in SAP system, and the Chief chemist will do the
usage decision to release the material.

8.4.2 Laboratory Fine Chemicals

8.4.2.1 Warehouseman/Storekeeper will check for all the documents upon arrival of laboratory
chemicals on site.

8.4.2.2 The chemist will check and inspect the chemicals;

 The physical appearance of chemical bottles (deformed bottles and partially
 Opened cap will not be accepted)
 MSDS should be available
 Expiration date
 Quantity of chemicals as per the Purchase Requisition
 Fabricated cans or not fit for purpose shall not be allowed.

8.5 Bulk chemical quantity acceptance

The bulk chemical quantity shall be verified before acceptance. Chemicals which are packed in IBC,
drum, plastic canes, bags should be not damaged condition. For the chemicals which delivering by the
tanker such as Hydrochloric acid & caustic soda, there are two methods to verify the quantity as
follows

Method: 1 To verify the Bill of Lading/Manifest from the delivery driver matches the tank that the
chemical is being unloaded into. (Refer Record#______)

Method: 2 To seek the weighbridge receipt and compare the chemical bill of lading.

8.6 Chemicals considered to be Carcinogens and Mutagens

8.6.1 Carcinogens and mutagens as much as possible should be prohibited on site. Chemical
department should investigate consideration a substitute for these kinds of chemicals if in case
necessary.
8.6.2 The laboratory should have a copy of all the MSDS of the chemicals available in the laboratory as
well as the MSDS of bulk chemicals and laboratory staff must be familiar with it.

8.7 Purchase of new chemicals or chemical substances brought on site by sub‐ contractors

Uncontrolled, if printed *Refer latest version in the server *If required, print both the sides*
ROMCO/OPN/SP-066 Rev: 00 Rev. Date: 11 NOV 2020 Page 7 of 9
 Chemical Management
Purchase of new chemicals to be used in the plant should undergo prudent examination and within
the approval of the chief chemist. Several points are to be considered in case of buying new chemicals
or bringing up chemicals on site by the contractors.
 For what purpose is it going to use
 Can the chemical be managed safely when it arrives?
 Is it hazardous chemicals or a controlled substance or what are the hazards associated by
these chemicals?
Ensure that the chemical contractor or suppliers are qualified for supplying chemicals and certificate
of authorization should be asked for and maintained a copy of it.

Those chemicals brought on site by the sub‐ contractors should pass with the quality checking of the
chemistry department.

8.7 Waste Disposal

 Empty drums, sacks, pails, and chemical canisters will be collected by a contractor who is accredited
by GAMEP certified vendor.
 Collected chemical waste from spillage will be placed in appropriate container and will also be
collected by the chosen contractor accredited by GAMEP certified vendor.

9. Record

Retention
Record Number Record Title Responsibility
Period
ROMCO/OPN/SP-066/FM001 Rabigh IPP Chemical Unloading Checklist
Chief Chemist 5 Years
(From chemical truck)
Rabigh IPP Hydrochloric acid unloading
ROMCO/OPN/SP-066/FM002 Chief Chemist 5 Years
check (From IBC Tank)
Rabigh IPP Liquid Ammonia (Boiler Feed
ROMCO/OPN/SP-066/FM003 Chief Chemist 5 Years
water) handling check list
ROMCO/OPN/SP-066/FM004 Rabigh IPP RO Chemical handling check list Chief Chemist 5 Years

Rabigh IPP chemical preparation checklist

ROMCO/OPN/SP-066/FM005 Chief Chemist 5 Years
(CIP tank)
Rabigh IPP Unloading Chemicals quantity
ROMCO/OPN/SP-066/FM006 Chief Chemist 5 Years
receipt

10. Legal requirement & References

 ISO 45001:2018
 Material Safety Data Sheets of all bulk Chemicals at Rabigh IPP.
(Refer to MSDS file which available with Chemical Department)
 Material Safety Data Sheets of Laboratory Fine Chemicals
(Refer to MSDS file available with Chemical Department)

Uncontrolled, if printed *Refer latest version in the server *If required, print both the sides*
ROMCO/OPN/SP-066 Rev: 00 Rev. Date: 11 NOV 2020 Page 8 of 9
 Chemical Management
11. Document Revision History

Revisio
Date Brief Description of changes from the previous version
n No.

00 11 Nov 2020 First Issue

Uncontrolled, if printed *Refer latest version in the server *If required, print both the sides*
ROMCO/OPN/SP-066 Rev: 00 Rev. Date: 11 NOV 2020 Page 9 of 9