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Vacuum Truck Operations

Vacuum Truck Operations. CAER Safety Summit – June 2012. Gulf Coast Fatality – Incident learnings. 2007 a Vacuum Truck Helper was Exposed to H2S Vapors due to Incompatible Materials Reacting Inside the Vacuum Truck.

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Vacuum Truck Operations

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  1. Vacuum Truck Operations CAER Safety Summit – June 2012

  2. Gulf Coast Fatality – Incident learnings • 2007 a Vacuum Truck Helper was Exposed to H2S Vapors due to Incompatible Materials Reacting Inside the Vacuum Truck. • The Truck was Drained, but not Cleaned, after Recovering Material from a Previous Chemical Cleaning Job. • Established Procedures Must Be Followed and Reinforced • The Work Permit did not Include Vacuuming Material from the Secondary Containment (Which Contained Acid) • Work Permits Must Be Specific and Must Be Followed • The Vacuum Truck Company added a Second Truck to the Job, without contacting Operations • All Personnel who Sign-on a Permit Must Read and Understand it AND Proposed Changes Must be Approved by Operations. • The Vacuum Truck Operator and Helper did not Properly Respond to the PHM Alarms by Immediately Leaving the Area • All Personnel Must Evacuate the Work Area without Exception

  3. Vacuum Truck Basic Principles of Operation • Training and Awareness • Clean Tanks and Vacuum Pumps • Product Identification • Mixing of Materials – Not Allowed • Static Electricity Management • Control of Vacuum Pump Vapors • Personal H2S Alarm Actions • Defined and Controlled Offloading

  4. Training and Awareness • Contract Vacuum Truck Operators must be trained: • API Recommended Practice 2219 for Safe Operation of Vacuum Trucks in Petroleum Service • Their Company Specific Vacuum Truck Procedures • Loading, Unloading, Venting, Bonding/Grounding, Continuity Checks, Scrubbers, etc • HAZWOPER Certified • Workers working with vacuum truck operators (Plant Operators, Mechanics, Supervisors, etc) must have Awareness training in the principles of Safe Vacuum Truck Operations. • Unit Operators must be specifically trained to be familiar with the Vacuum Truck Checklist and the Offloading Matrix.

  5. Vacuum Truck Checklist • All Vacuum Trucks Loaded and/or Unloaded must have a completed Refinery Vacuum Truck Checklist. • Date – Driver - Company • Identify Material to be Loaded • Verify Clean Tank & Pump • Scrubbing System Needed? • Loading & Offloading Locations • Designated Location • Operator Signatures • Permits Needed • Bonding & Grounding • Positioning & Venting • Electrical Continuity Verified • Hard Connections < 15 psi

  6. Clean Tanks and Vacuum Pumps To Prevent Possible Harmful Chemical Reactions: • The tank and pump must be cleaned after each load, except: • When Returning to the Same Location to Load the Same Material, or • When Performing a Repetitive Job Order with Known Materials-Characteristics (typically Hydrocarbon on Hydrocarbon) e.g. Slops Barrels Pick-up Runs • Vacuum Trucks are cleaned at the End of Each Day to Prevent the Possibility of a Dirty Truck being used on an After-Hours Callout. Note: Any Truck Left Dirty Must Have its Keys Locked in a Lock Box that is Only Accessible by a Maintenance Supervisor and a Form Must be Completed Describing the Material Last Loaded.

  7. Product Identification • All Materials Loaded onto a Vacuum Truck must be Positively Identified. • The Operator or Equipment Owner is Responsible to Positively Identify the Material to be Loaded and the Properties of the Material. • Flammable or Combustible • H2S or Other Toxic Characteristics • Corrosive Material

  8. MIXING OF MATERIALS NOT ALLOWED • Materials May Not Be Mixed! • Exception is Hydrocarbon on Hydrocarbon with a Repetitive Job Order • These Jobs are Done Several Times per week from Designated Pick-up Locations • Materials are Similar and Compatible

  9. Static Electricity Management • Vacuum Truck Hoses Undergo Continuity Checks and Scheduled Inspections • Each Time a Vacuum Truck is Loaded the Vacuum Hose and Grounding Wire are Checked for Electrical Continuity • Plastic Containers Are Not Used to Catch Flammable or Combustible Liquids

  10. Control of Vacuum Pump Vapors • Gasoline Range Materials Must Be Loaded by Alternative Means: • Butanes and Similar Materials are Not Loaded • Light Hydrocarbons May be Pumped (BY USE OF A POSITIVE DISPLACEMENT PUMP) onto the Truck, or • Prior to Loading a Vacuum Can be Established to Draw the Material onto the Truck without Running the Pump • Caustic Scrubbers are Used to Reduce H2S Emissions • Vacuum Pump Hoses are Extended At Least 50’ to a Safe Location to Prevent Fire or Harmful Exposure to Personnel

  11. Personal H2S Alarm Actions • Any Job Requiring Vacuum Truck Operators to Wear Fresh Air Must Have a Specific Procedure • Virtually Never Done - Alternative Means Are Used • All Vacuum Truck Operators / Helpers Must Wear a PHM • All Plant Workers Must Wear PHMs, it is Emphasized for Vacuum Truck Operators • All Vacuum Truck Operators / Helpers Must be Aware of What Actions to Take in the Event of a PHM Alarm • All Personnel Must Be Aware of Actions to Take, it is Emphasized with Vacuum Truck Operators

  12. Defined and Controlled Offloading • All Materials Loaded onto a Vacuum Truck Must have a Designated Offloading Location Prior to Loading. • The Operator or Equipment Owner is Responsible to Designate the Offloading Location According to a Pre-Identified Offloading Matrix to Ensure Material Compatibility

  13. Questions

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