ISOPA Driver Training Program Revision 2015 1 Driver Product & Safety Training MDI / TDI Bulk Liquid...

ISOPA Driver Training ProgramRevision 20151

Driver Product & Safety Training

MDI / TDI Bulk Liquid Transportation



Driver Training MDI / TDI

Company [name]

Location [place]

Date 19/04/23

Trainer [name]


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


Introduction ISOPA

European

ISOcyanate Producers Association

See website www.isopa.org

Member companies:

olyo


ISOPA Member Companies


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


Appearance

Liquid Reacted

MDI

Clear to brownSlightly musty

BrownCrusty

TDI Clear to pale yellowSharp, pungent

WhiteFoamy


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


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!



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.)


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



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


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 !


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


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


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


Product Transport Use

MDI Not regulated but still harmful

TDI ADR / RID / IMDGUN 2078Class 6.1Packing Group IIMarking and Labelling:ADR tunnel category: (D/E)

Classification and Placarding

602078


PPE – MDIPersonal Protective Equipment

Hard hat Goggles Liquid-tight gloves Safety shoes / boots Overall Eyewash bottle

As a minimum...

• Butyl rubber• Neoprene• Nitrile rubber


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

Filter to be replaced after 2 days unless different guidance from

supplier


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 isocyanates

You should not use

contact lenses when

handling isocyanates


Personal Health (1)

Use an appropriate cartridge / canister (min. AP2)

Filter to be replaced after 2 days unless different guidance from supplier


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 !


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)


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


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 system2. Absorb the spill3. Neutralise4. Wait (30–60 minutes after reaction has finished)5. Remove spill after reaction has finished.6. Put residues in designated chemicals waste bin7. Apply decontamination fluid


Loading: Key Items

PPE must be worn

Tank equipment

3-Minutes check before & after loading


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)


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


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!)


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


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?


Transport

Hours / Speed

Check temperature (and pressure)

Reporting unsafe conditions / incidents

Parking


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/


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


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)


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)


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)


Discharge Methods (1)Customer liquid pump and vapor return

(with hoses provided

by customer, if possible)


Discharge Methods (2)Customer nitrogen or dry air


Discharge Methods (3a)Vehicle compressor with silica gel


Discharge Methods (3b)Vehicle compressor without silica gel


Spillage Tray Lay-out (example)

Liquid line and vapour return line should be properly identified

Vapour

Liquid

Pressure


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?


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


Near Misses & Unsafe Conditions

Iceberg Theory

Near misses & Unsafe conditions

Incidents


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


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 !)


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


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


And ......

In any case of emergency:

call us ....

don‘t try to be a hero.....!!


Emergency Response

TDI Danish incident French incidents Portuguese incident Swedish incident Turkish incidentsHungarian incident

MDI British incident German incident Italian incident

– Packed– Bulk– Bulk– Bulk– Bulk- Bulk

– Bulk– Bulk– Bulk


Emergency Response

Emergency incident scenario

– What went well ?

– What can be improved ?


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


The End

Congratulations!

Certificates will be forwarded as soon as possible


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.

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