Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology

Chemical Engineering Department

Basic
Safety
Measures

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

Dust for Diphenolic Acid Production

Technical
Study

Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology
Chemical Engineering Department

COCOPHENOL CORPORATION BASIC SAFETY MEASURES

Cocophenol Corporation adapted the following safety measures in order to

prevent unwanted incidents and injuries from occurring. The safety measures were in
line with the Occupational Safety and Health Standards (As Amended, 1989) of the
Department of Labor and Employment Philippines. The safety measures were divided
into the following aspects:
1) Personal Safety;
2) Working Environment;
3) Fire Protection and Control; and
4) Health Services.
Personal Safety includes the basic safety guidelines that the employees must
strictly observe in the workplace at all times and the mandatory use of the Personal
Protective Equipment (PPE) in the workplace at all times.
Safety in the Working Environment includes the measurement of the atmospheric
working environment and other elements in the workplace that the workers have to
interact with every day. This also includes the proper storage of the chemicals used, the
machine guarding for screw conveyors, provisions in electrical safety, identification of
piping system, and emergency precautionary measures.
Fire Protection and Control is the aspect of safety that deals with the prevention
and control of fire. This includes the building construction, fire-fighting facilities, alarm
systems and emergency drills.
Lastly, the company also includes Health Services in order to cater the medical
needs and other emergency situations that require immediate medical attention.

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

Dust for Diphenolic Acid Production

Technical
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Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology
Chemical Engineering Department

I. PERSONAL SAFETY
BASIC SAFETY RULES & GUIDELINES
These basic safety rules and guidelines were formulated to promote a
harmonious and safe working conditions among workers. It is a must that they keep in
mind and strictly adhere to these guidelines at all times.
1) All workers are required to be familiar with the equipment, machines, and tools that
they are tasked to operate. They must read and keep in mind at all times all the
instructions and manuals supplied along with their respective equipment.
2) Always pay attention when inside the workplace. Music, cellphones, and other
forms of distraction are strictly prohibited during work hours.
3) Employees must report any medical emergencies immediately. Make sure
everyone has an easy access to medical equipment and emergency materials.
4) Workers must focus on the task assigned to them. But at the same time, every
worker has to keep an eye on each other so that they will be aware if something is
wrong.
5) The work area should always be kept clean and free from obstructions. The
manufacturing area should be clean, light, and well organized. Make sure that
there is plenty of space to work on.
6) Smoking is not allowed inside the plant. Smoking is only allowed in the designated
smoking area outside the facility.
7) An employee shall never attempt to perform a task for which he/she has not been
trained.

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

Dust for Diphenolic Acid Production

Technical
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Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology
Chemical Engineering Department

PERSONAL PROTECTIVE EQUIPMENT AND DEVICES

To protect the workers from the hazards present in
the working environment, the workers were required to
use proper personal protective equipment and devices
(PPEs). Under Rule 1080 (Personal Protective Equipment
and Devices), section 1081.04: no person shall be
subjected or exposed to a hazardous environmental
condition without protection. All PPEs issued are of the
approved design appropriate for the exposure and work to
be performed. The following are the PPEs issued to the workers of Cocophenol Corp.s
manufacturing facility:
1. Eye and Face Protection
Due to the presence of chemical vapors in the
workplace, the workers are issued with face shield (full
length) and splash goggles to protect their eyes and face.
The following chemicals are present in the workplace:
NaOH, HCl, phenol, the main product, Diphenolic acid
and the intermediates/ by-products levulinic acid and
formic acid. These chemicals require proper eye and face protection when handled.
Spectacles which provide optical correction are also issued to the workers who
require corrective lenses.
2. Head Protection
Acid Hydrolysis and Catalytic Condensation of Coconut Coir
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Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology
Chemical Engineering Department
Hard hats are required in the facility in order to
ensure the protection of the workers from impact
penetration from falling and flying objects, blows, and from
limited electric shock and burns. The hard hats issued
have the following specifications:
1) made

of

non-combustible

or

slow-burning

materials,
2) total weight should be 0.45 kg (16 ounces) or less,
3) have a brim all around to provide protection for the head, face and back of the
neck, and
4) cradle and

sweatband

are

detachable

and

replaceable.
3. Hand and Arm Protection
Gloves are required for workers that will be handling
corrosive substances such
as acids and bases. They

are made out of natural

rubber, synthetic rubber, or

pliable

plastic

material

resistant to corrosion.
4. Body Protection
Lab

coats

are

required inside the facility as

a defensive measure for

chemical spills. Full suits

are also present in the

facility (on stand-by) in case

of large spill.
5. Safety Shoes
Use of safety shoes are mandatory inside the
facility for the protection of the feet and legs from injuries.

II. WORKING ENVIRONMENT

WORKING ENVIRONMENT MEASUREMENT
Working environment measurement (WEM) means the sampling and analysis
carried out in respect of the atmospheric working environment and other fundamental

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

Dust for Diphenolic Acid Production

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Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology
Chemical Engineering Department
elements of working environment for the purpose of determining actual conditions
therein. Cocophenol Corporation strictly observes the implementation of working
environment measurement to maintain and control the working environment in
comfortable and healthy conditions for the purpose of promoting and maintaining the
health of the workers.
1) Working environment measurement includes temperature, humidity, pressure,
illumination, ventilation, concentration, of substances and noise.
2) The records of measurement are made available to the enforcing authority.
3) WEM is performed annually. It is performed by the medical personnel of the
company.

RULES IN STORAGE AND HANDLING OF HAZARDOUS MATERIALS

Since Cocophenol Corp.s manufacturing facility deals with the manufacture of
Diphenolic acid, and utilizes hazardous chemicals such as phenol, NaOH, and HCl, it
needs to comply with the provisions of Rule 1090 (Hazardous Materials). This ensures
that the employees exposure are kept to a minimum.
1. Storage Tanks
In Cocophenol Corp.s manufacturing facility, both the HCl and phenol are stored
in storage tanks. These storage tanks conform to sections 1096.01 and 1096.02 of Rule
1090:
1) They are surrounded by pits of sufficient size to hold the entire contents in
case of rupture.
2) They are located above ground level.
3) They are covered with protective paint to prevent corrosion from moisture or
fumes.
4) They are provided with permanent ladders/ stairways and platforms for
convenient and safe access to all parts of the tank.
5) Tanks are not placed above passage ways.
2. Marking of Containers
All containers with hazardous substances shall be properly labelled. Any
container of hazardous substances for use, handling or storage shall not be accepted
unless such container is labelled.

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

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Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology
Chemical Engineering Department
Specific Labelling Requirements
Labels shall contain the following information:
1.
2.
3.
4.
5.

symbol of the relevant category of hazard of the substance contained;

trade name in addition to the chemical name of the substance;
a description of the principal risk or risks;
a statement of the necessary precautions to be taken; and
if necessary, a statement of the first-aid or other simple measures to be taken in
case of injury or emergency.

3. Testing of Atmosphere
The atmosphere of workrooms are tested annually to ensure that the
concentration of irritating or toxic dusts, fumes, gases, mists or vapors are kept within
the threshold values:

HCl 5 ppm
NaOH 2 mg per cubic meter of air
Phenol 5 ppm
Diphenolic Acid 1 mg per cubic meter of air

4. Cleaning
Where toxic and irritating substances are being handled, manufactured or used,
the floors, walls, structural surfaces, work benches, tables and equipment are thoroughly
cleaned daily by means of vacuum cleaning, wet brushing or sweeping, outside of
working hours.
5. Precautionary Measures for Emergencies
Warning Devices
In all workplaces where hazardous substances are manufactured, handled or
used, suitable warning device were installed wherever possible, to alert the personnel in
case of the liberation of dangerous quantities of said substances.
Training of Personnel
Workers are trained on procedures to control the liberation of hazardous
substances, eliminate pollution, and to evacuate from the affected area in an orderly
manner.
6. Spillage

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

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Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology
Chemical Engineering Department
Spillage of irritating or toxic substances shall be removed as quickly as possible
by the best technical and scientific means possible and available.

7. Instruction on Health Hazards

All workers are thoroughly informed of the health hazards associated with their
work and the measures to be taken to protect themselves there-from.
8. Meals
The introduction, preparation and consumption of food, drink and tobacco in the
workroom is strictly prohibited.
9. Personal Cleanliness
All workers are required to wash their faces and hands thoroughly before eating,
drinking, smoking, or before leaving the premises since they are exposed to toxic
substances which may enter the body through ingestion.
10. Medical Aid
All workers are required to report promptly any physical complaints.
11. Exposure Records
The company maintains accurate record of employee exposure to potentially
toxic materials. These are required to be measured and monitored. This record is open
to authorized agents and the workers exposed to such hazards.
12. Handling
All handling of corrosive or hot liquids in the plant are done by pumps and
pipelines. Transporting in small containers are eliminated in order to minimize the
exposure of the workers to the substances.
13. Spillage of Acids and Alkalis
1) Floors are kept as dry as possible
2) Spillage are avoided. Spilled corrosive liquid are guarded until removed to
prevent workers from stepping or getting into contact with it.

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

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Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology
Chemical Engineering Department
3) Spilled or escaping corrosive acid are flushed out with water or neutralized with
chalk or lime. Absorbing the spill by waste cloth or other organic materials are
strictly prohibited.

14. Physical Contact with Corrosive Substances

1) It is mandatory for the employees to use protective and equipment conforming to
the requirements of Rule 1080.
2) Workrooms are installed with clean running water, and quick operating eye
fountain and shower baths. They are maintained in or adjacent to the workrooms
readily accessible to all workers

MACHINE GUARDING SYSTEM: CONVEYORS

All screw conveyors installed in Cocophenol Corp.s manufacturing facility
conforms to the provisions under section 1205.08 of Rule 1200 (Machine Guarding):
1) All screw conveyors are completely covered with substantial lids.
2) All screw conveyors are guarded by standard railing guards to prevent the
materials handled from falling on and causing injury to employees.

ELECTRICAL SAFETY
Electrical installation in Cocophenol Corp.s manufacturing facility conforms to
the Philippine Electrical Code and Rule 1210 (Electrical Safety).

IDENTIFICATION OF PIPING SYSTEM

Piping identification is necessary to let workers trace process problems and find
solutions faster. With this, the workers are aware of what materials are conveyed in the
piping systems. Identification of piping system of Cocophenol Corp.s manufacturing
plant is in accordance with Rule 1230.
Positive identification of contents of piping systems are primarily stencilled or
lettered legends giving the name of the content in full abbreviated form. To supplement

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

Dust for Diphenolic Acid Production

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Pamantasan ng Lungsod ng Maynila

College of Engineering and Technology
Chemical Engineering Department
this, the pipelines were painted with respective colors corresponding to what they
contain inside:
Water Piping Blue
Steam Piping Red
Process Piping White
Other Fluids (including drainage pipe) Black

Acid Hydrolysis and Catalytic Condensation of Coconut Coir

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10

III.FIRE PROTECTION AND CONTROL

Fire protection is one aspect that is needed to
observe in any facility. In accordance with Rule 1940
(Fire Protection and Control), Cocophenol Corp.
adapted the following to ensure fire safety:

BUILDING CONSTRUCTION AND FACILITIES

1. Exits
1) At least two exits are provided in every floor
as well as the basement of every workplace;
capable of clearing the work area in five (5) minutes.
2) Safe, continuous and unobstructed passageways are provided and maintained to
have a minimum width of at least one meter, but not less than the width of the
exit.
3) No steps or stairs are placed in horizontal exits as they may cause tripping and
may lead to injuries. When theres a difference in level between cemented floor
areas, ramps or inclines of not more than one to ten (1 to 10) slopes are
installed.
2. Stairways
1) All stairways used as fire exits lead directly to the street.
2) All approaches to fire exits are cleared of any obstruction and are properly
marked to make the direction of egress clear.
3. Fire Doors
1) Stairway enclosures, fire exits and partitions are provided with fire doors of the
self-closing type and easily opened from either side towards the line of travel in
leaving the building.
2) Doors that give access to stairways are configured in a way that they do not
open directly on stairs, they are to open on landings leaving a path of travel
equal to a less the width of the door at any point during its swing.
3) Doors swinging on both sides, vertical sliding doors, rolling shutters and
revolving doors are not allowed as exits.
4) Doors from stairways to the outside of the building have a width equal to at least
the effective width of the stairs.
5) Doors leading into or out of any building or floor are not locked or fastened
during period of occupancy.

FIRE-FIGHTING FACILITIES
To ensure safety against fire, the manufacturing facility adapted certain firefighting measures in-line with section 1944 of Rule 1940.
1. Water Supply
Supply system, including tanks and pumps, are located and protected that their
operation or use will not be impaired by a fire in the workplace.
2. Hydrants
a) Hydrants are of the same types and sizes as those used by the local public fire
department. They are located and protected that they will not be exposed to
mechanical damage from vehicles.
b) Hose couplings, outside hydrants and standing nipples are of the same type and
size as those used by the local public fire department.
c) Hose are thoroughly drained and dried after each use, and tested at least once
every four (4) months.
3. Portable Extinguisher
In accordance to section 1944.05 of Rule 1940, all places of employments are
provided with portable fire extinguishers for protection against incipient fire.
a) These portable extinguishers are maintained in fully charged and operable
condition and kept in their designated places at all times when not in use.
b) Only approved fire extinguishers are used in the facility.
c) Extinguishers are installed on hangers or brackets conspicuously located in
unobstructed areas readily accessible in the event of fire.
d) Extinguishers having a group weight not exceeding 18 kilograms are installed so
that the top is not more than 1.5 meter above the floor. Those exceeding 18 kg,
except wheeled types, are installed not more than 1 m. above the floor.
e) Extinguishers are inspected monthly to ensure that they are in their designated
places, to determine physical damages and that they are in good operable
f)

condition.
On the place where the extinguishers are located, the type and use of the
extinguishers and instructions on its proper use are marked in visible and easily
readable letters.

ALARM SYSTEMS
Sounding Devices

1) All buildings having two or more stories in height are equipped with fire alarm
system and signals of distinctive quality and pitch clearly audible to all persons
inside the building.
2) Hand-operated sending stations of fire alarm boxes are provided on every floor
and located that the travel to reach a station is not more than thirty (30) meters.
3) Fire-alarm stations are conspicuous, readily accessible, and in the natural path
of escape from fire.

EMERGENCY DRILLS
Emergency drills (fire and earthquake) are conducted at least twice every year to
maintain an orderly evacuation. These shall only include evacuation of persons and shall
not include salvage operation.

IV. HEALTH SERVICES

A clinic is designated to cater the medical needs and other situations that require
immediate medical attention. A minimum quantity of medicines, medical supplies, and
equipment are provided and are kept inside the treatment room. A company nurse was
assigned in the clinic. The clinic provides the following medical services:

Basic first aid treatment;

Check-up and consultation; and
Health education for sickness prevention.