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Safe transfer of Dangerous Goods

Safe transfer of Dangerous Goods. A consigners perspective Nathan Dixon, Process Safety Advisor Joel Lyons, Cyanide Despatch Supervisor. Wesfarmers Chemicals, Energy & Fertilisers. In FY2012 divisional EBIT was US$265 million on net assets of US$1.3 billion. WESCEF businesses. 50%. 75%.

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Safe transfer of Dangerous Goods

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  1. Safe transfer of Dangerous Goods A consigners perspective Nathan Dixon, Process Safety Advisor Joel Lyons, Cyanide Despatch Supervisor

  2. Wesfarmers Chemicals, Energy & Fertilisers In FY2012 divisional EBIT was US$265 million on net assets of US$1.3 billion

  3. WESCEF businesses 50% 75%

  4. CSBP business overview QUICK FACTS • Based in Kwinana since 1967 • 15 manufacturing plants • 3 Major Hazard Facilities • 180 chemical customers • 5,000 fertiliser customers CSBPChemicals CSBPFertilisers Wesfarmers Chemicals, Energy & Fertilisers head office

  5. Our people • CSBP employs 720 people, including more than 530 Kwinana-based employees • ~70% of our Kwinana-based employees live in our local community • In FY15 CSBP paid more than $79 million in wages, and in addition WesCEF paid more than $57 million to suppliers based in the Kwinana-Rockingham area • We are committed to the development, safety and well-being of our people CSBP employees

  6. Our site 138 hectare site and our neighbours are BP, Tronox and Coogee Chemicals Built in 1965 as fertiliser works with rail load out facilities for 180lb bags Over time, manufactured Hydrochloric Acid, Sodium Hydroxide, Chlorine, Phosphoric Acid, Ammonia, Sulphuric Acid, Nitric Acid, Sodium Cyanide, Ammonium Nitrate and various Fertilisers

  7. Movement of Dangerous Goods Road Ammonium Nitrate liquid, solid and Emulsion, Sodium Cyanide solid, Sulphuric Acid Rail Ammonia, Sodium Cyanide liquid Pipelines Ammonia, Natural Gas, Hydrogen, Carbon Dioxide Ship Ammonia, Ammonium Nitrate solid, Sodium Cyanide solid

  8. Legislation relating to Dangerous Goods • DG Safety Act 2004 DG Safety (Road and Rail Transport of Non-Explosives) Regulations 2007 DG Safety (General) Regulations 2007 DG Safety (Storage and Handling of Non-explosives) Regulations 2007 DG Safety (Major Hazards Facilities) Regulations 2007 • Australian Code for the Transport of DG by Road & Rail 7th Edition • Petroleum Pipelines Act 1969 Petroleum Pipelines (Management of Pipeline Operations) Regulations 2010 • Rail Safety National Law (WA) Act 2015 Rail Safety National Law (WA) Regulations 2015 • ICMI Code for the Manufacture, Transport and Use of Cyanide in the Production of Gold

  9. Registrations • DG Act – 2 MHFs @ CSBP – Ammonia/AN and NaCN • Operate under Safety Report Regime • Pipelines Act – 1 licenced Pipeline • Operate under Safety Case Regime • Rail Act – CSBP is Accredited Rail Transport Operator (RTO) CSBP Registered Infrastructure Manager for its 2 private rail sidings (@ SCP & ALF)

  10. Private Sidings Ammonia Loading Sodium Cyanide

  11. Liquid Sodium Cyanide - Isotainers 18kL Isotainer

  12. Liquid Sodium Cyanide - Isotainers 22kL Isotainer

  13. Liquid Sodium Cyanide – Loading The loading installation includes the following components: • Rail siding for standard gauge wagons, main line and shunt line. • 4 x Loading platforms to provide access to the top of the isotainers. • Bunded rail loading area, drainage to the tank farm sump. • Designed to load 4 x 22kL Isotainers simultaneously through articulated loading arms fitted with Kamvalokcouplers @ At 400m3/hr. • Amount to be loaded is controlled by mass measuring equipment. • Displaced air from the containers is vented to atmosphere. • RFID feedback to the DCS for pre-determined fill set points.

  14. Potential Hazards associated with NaCN filling • Loading Hose failure • Overfilling of isotainer • Loss of containment from despatch pipework • Movement of isotainer/wagons during loading • Cyanide exposure during coupling/decoupling

  15. Controls for Liquid Sodium Cyanide Loading • Emergency response plans • Trained and competent loading operators in PPE • High level switch in vent lines, mass cut-off logic, volumetric cut-off logic • Preventative maintenance, including trip checks • Shunting procedure and high rail vehicle • ‘No motion’ proximity switch to detect uncontrolled rail movement and cut off fill • Isotainer inspection activities – planned inspections

  16. Unimog High Rail Vehicle

  17. PotentialHazards associated with Rail • Person crushed/caught between wagons • Collision when shunting within private rail siding • Collision with fouled vehicles • Out of control movement • Loss of Containment during shunting operations within private rail siding

  18. Controls for Rail • Shunting procedure including 3 step protection in danger zone • Line of sight of operator piloted by spotter on radio • Very low shunting speeds (7km/hr) • Track maintenance and inspections • Use of train brake for all movements, emergency air dump handle fitted to hi-rail shunt vehicle • Train operators aware of incompatible materials and separation distances

  19. Ammonia Loading Facility (ALF)

  20. 44t Anhydrous Ammonia Bullets Filling Pressure 500kPa @ approx 800 l/min

  21. PotentialHazards associated with Ammonia Loading • High pressure in loading arm • High level in Isotainer • Ammonia release from loading arm • Movement of Isotainer during filling • Ammonia release causing chemical asphyxiation or burns

  22. Controls for Ammonia Loading Facility • High pressure trip • Gas Detection automatic shutdown • High level trip • Local ESD with water curtain sprays • Low Pressure trip • Gas and liquid arm proximity switched • Visual checks, including one by second operator • Trained and Competent personnel with PPE • Use of thermal camera to determine returned level

  23. Emergency Response Support • CSBP provides Emergency Response and technical support for all its products whether on road or rail, on or offsite. • Dedicated Incident Management Team, Emergency Response Team • MoU with BIS (Brambles Industrial Services) for support nearer to Kalgoorlie

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