FOREWORD

Growing consumption of fossil fuels is leading to greater economic and strategic vulnerability for India. These concerns
are driving a search for viable alternatives to gasoline as a transportation fuel, and many experts consider ethanol as
one that can make a very large difference in a relatively short time.

The world over, ethanol is being blended with Motor Gasoline to boost its octane rating and also for reducing carbon
monoxide and other toxic emissions. It is a clean, grow-your-own type of fuel that can be produced on-site from locally
available renewable resources. Ethanol-blended petrol is a 'quality' fuel that improves the performance of the vehicle
engine while at the same time lessening harmful auto emissions, thus providing significant environmental benefits.
Bio-fuels like Ethanol have the added ability to bring down greenhouse gas emissions since they are primarily derived
from crops, which by nature absorb carbon dioxide.

At the same time, doping of ethanol in Motor Gasoline at petroleum storage points requires various health & safety
precautions during its handling, storage and dispensing.

It is with this purpose in mind that this Health, Safety & Environment Manual on Ethanol has been compiled by the
H, S & E Department of Marketing Head Office. It puts up guidelines on the various health, safety and environmental
protection measures to be taken while handling ethanol and ethanol-doped Motor Gasoline and is based on currently
available data and experience gathered till date. It is in an illustrative form and is meant to be made accessible to all so
that they can draw information and guidance from it, and practice and upgrade their safety methods.

I understand that H, S & E Department has compiled the information based on various standards, references and
practical knowledge gained in the field.

I congratulate the officers of H, S & E Department for having brought out the manual on Ethanol. I am confident that it
would go a long way in enhancing awareness among the employees to abide by the guidelines and procedures to
ensure the highest standards in health and safety.

(M Nene)
Director (Marketing)
1st August, 2012
 CONTENTS

Chapter Content Page No.

1. Introduction 1

1.1 What is Ethanol ? 1

1.2 What is Anhydrous Ethanol ? 1

1.3 Use of Anhydrous Ethanol in Automobile Engines as a Fuel ? 1

1.4 Denatured Anhydrous Ethanol 1

1.5 Salient features of denatured anhydrous ethanol 1

2. Properties of Ethanol: 2

2.1 Physical properties & Chemical properties 2

2.2 Regulatory and Health & Safety Information for Ethanol 2

3. Supply & Distribution system 4

3.1 Steps in Handling Ethanol 4

3.2 Production of Ethanol at Sugar Industry 4

4. Statutory Licenses and approval 5

5. Safety distances 6

5.1 Distance norms for Above ground tank in dyke of Petroleum product 6

5.2 Distance norms for separate dykes 6

6. Safety fittings of Tank Truck used for Ethanol Transportation. 7

6.1 Safety fittings of Tank Truck 7

7. Transportation of Ethanol

7.1 Precautions during Ethanol loading / unloading of Tank Truck ……

8. Safety of Ethanol Storage Tanks & Handling Facilities 9

8.1 Material of construction 9

8.2 Storage Tank Fittings 9

8.3 Corrosion Inhibitors for Ethanol 9

8.4 Colour Coding of Ethanol 9

9. Safety during Ethanol Storage Tank Cleaning 10

10. Doping of ethanol in motor spirit 11

Chapter Content Page No.

11. Safety during dispensing of Ethanol doped Motor Spirit 12

11.1 Underground Tanks, Dispensing Unit and Fittings 12

11.2 Unloading of Ethanol Doped Tank Truck at Retail Outlet 12

11.3 Dispensing of Ethanol Doped Motor Spirit 12

12. Electrical Safety 13

13. Fire and Explosion Hazards, Fire Fighting and Leak / Spillage 14

Management Procedures

13.1 Fire and Explosion hazards 14

13.2 Fire Fighting procedures 14

13.3 Fire Fighting procedures 15

13.4 Spill or leak Management procedures 16

14. Health hazards 17

14.1 Health hazards of Ethanol 17

14.2 Industrial hygiene and sanitation 17

15. Emergency First aid Procedures 18

15.1 Eye Exposure 18

15.2 Skin Exposure 18

15.3 Inhalation 18

15.4 Ingestion 18

15.5 Rescue Procedures 18

16. Personal Protective Equipment 19

16.1 Personal Protective Equipments for Handling Ethanol 19

16.2 Other Protection 19

16.3 Hygienic work practices 19

16.4 Ethanol leakages / Spills detection 19

16.5 PPEs for Emergency and for Rescue team 19

17. Disposal of Waste Ethanol / Ethanol doped Motor Spirit 20

Annexure-A: Material Safety Data Sheet of Ethanol 21

Annexure-B: Typical example for ATC Foam requirement for above ground Cone Roof Tank 22
storing Ethanol

Annexure-C: Typical example for ATC Foam requirement for above Ground Horizontal Tank 23
 Chapter-1

INTRODUCTION

1.1 What is Ethanol?

Ethanol is the pure chemical otherwise known as Hydroxyethane corresponding to the constitution CH3.CH2OH and a
Molecular Formula C2H50H.
Ethanol is used in pure or denatured state as a solvent or in medicines and colognes and cleaning solutions and rocket fuel;
proposed as a renewable clean-burning additive to gasoline.

1.2 What is Anhydrous Ethanol?

Anhydrous Ethanol is essentially Ethyl Alcohol, which is denatured and is meant for use as fuel in automobile engines.
Addition of denaturant makes unpleasant and unwholesome for potable purpose. But its addition to Anhydrous Ethanol will
not make unsuitable for blending with Motor Spirit or using in Automobile Engine.

1.3 Use of Anhydrous Ethanol in Automobile Engines as Fuel?

Currently 5% of Denatured Anhydrous Ethanol is being added to Motor Spirit (MS) in India. The very purpose is to reduce the
import of Petroleum Products and ultimately the outgoing foreign exchange. This concern about our country's dependence
on foreign for petroleum products is partly solved by adding 5% of Ethanol to Motor Spirit (MS).
Addition of Ethanol will also improve the Fuel Quality
i. By Increasing the Octane rating and
ii. It will provide Oxygen (O2) to decrease tail-pipe emission of Carbon Monoxide (CO). This will help in controlling the "Air
Pollution" partly.
It becomes necessary to develop "Guidelines on Safe Handling of Ethanol"; since Denatured Anhydrous Ethanol is being
handled at various stages such as transportation from dispatching location by road, unloading at our location, blending with
Motor Spirit and transporting, unloading and dispensing at Retail outlets.
1.4 Denatured Anhydrous Ethanol:
Denaturant is a substance completely miscible with Ethanol and of such a character that its addition makes the material or a
aqueous dilution unsuitable for potable purpose , its presence does not render anhydrous ethanol either as such or blended
with Petrol unsuitable for use in automobile engines.
Methanol, Turpentine, Ketones and Tars( High Molecular weight pyrosis products of fossil or non fossil vegetable matter) are
not to be used as a Denaturant for Ethanol to be used as a fuel in Automotive Engines. Also, Denaturants such as a higher
Aliphatic Alcohol or Ether not having adverse effects on Motor Spirit -Ethanol Blend or on automobile engine or fuel systems
shall be used.
Names of Denaturants to be used are Crotonaldehyde and Denatonium Sachhcride.
5% vol/vol of "Denatured Anhydrous Ethanol" is being added to Motor Spirit which is confirming to Motor Gasoline
specifications.
Denatured anhydrous Ethanol for fuel is made unfit for use on beverage by the addition of denaturants as per IS:15464 for use
in automotive fuel specifications.
1.5 Salient Features of Ethanol:
1.5.1 Ethanol is completely soluble in water, which presents potential problems for storage and handling. Ethanol will not
be significantly degraded by small amount of clean water, though water addition dilutes its value as a fuel.
1.5.2 A higher conductivity suggests that Ethanol will dissipate static charges that build up when pumping fuel during fuel
transfer faster than Motor Spirit. This given Ethanol a safety advantage over Motor Spirit as generated static
electrical charges will get dissipated more quickly.
1.5.3 Auto-ignition Temperature of Ethanol is significantly higher than that of Motor Spirit. This makes Ethanol less
susceptible to ignition when spilled on hot surface such as engine exhaust manifold.
1.5.4 The lower flammable limit of Ethanol is higher than motor spirit.
1.5.5 Flame of Ethanol is less bright than Motor Spirit flame. However Ethanol doped Motor Spirit flame is also visible.

1
 Chapter-2

PROPERTIES OF ETHANOL
(AS PER IS 15464:2004 & INDUSTRIAL MANUAL ON ETHANOL)

2.1 Physical & Chemical Properties of Ethanol:

 Chemical Name : Ethanol
 Other Names : Ethyl Alcohol
Absolute Alcohol
Ethyl Hydroxide
Ethylic Alcohol
Hydoxy Ethane
 Chemical Formula : C2H50H
H H
| |
H- C - C- H
| |
H H
 Molecular Weight : 46.07
 Ethanol content % by volume at
15.6/15.6 0C, Min(excluding denaturant) : 99.50
 Physical State : Liquid
 Appearance : Clear and Colourless
 Odour / Taste : Etheral odour
 Solubility in water@210C% by volume : 100% Miscible with water
 Solubility in organic Solvent : Soluble in most organic solvents
 Boiling Point(oC) : 78oC
 Relative Density at 15.6/15.6 0C Max : 0.796 gm / ml
 Vapour density (air=1) : 1.59
 Vapour pressure : 0.35-1.05 kg/cm2 at 37oC
 Viscosity : 1.200 cP @ 200C
 Alkalinity : Nil
 Acidity (as CH3COOH) mg/l , Max : 30
 Conductivity μS/m, Max : 300
 Aldehyde content as CH3(CHO) mg/l, Max : 60
 Methyl Alcohol, mg/l, Max : 300
2.2 Regulatory and Health & Safety Information for Ethanol:

2
  CAS Number : 64-17-5
 UN Number : 1170
(Blue colour indicates Health, 2-Intense or continued but not chronic exposure could cause temporary incapacitation or possible
residual injury.(eg Ethyl Ether)
Red colour indicates Flammability & 3 - Indicates Liquids and solids that can be ignited under almost all ambient temperature
conditions (e.g., gasoline). Liquids having a Flash point below 23°C (73°F) and having a Boiling point at or above 38°C (100°F) or
having a Flash point between 23°C (73°F) and 38°C (100°F).
Yellow colour indicates Instability/ Reactivity & 0- indicates normally stable, even under fire exposure conditions, and is not reactive
with water (e.g. helium)
 HAZCHEM Code : 3 YE
(3- Foam, Y- Violently/Explosively & use Breathing
Apparatus E-Area in at least 300 m to be evacuated)

 HAZCHEM LABEL :

 Flash Point : 13oC (Method closed cup)

 Auto Ignition Point
a) Fuel in air percentage : 3-19
b) Temperature (approx.) : 4550C
 Flammability limit lower : 4.3%
 Flammability limit upper : 19%
 TLV : 1000 ppm
 Toxic dose - LD50 : 7060 mg / kg (oral rat)
 Reactivity : Thermal decomposition or burning
will release oxide or carbon
 Reid Vapour pressure : 2.3 psi
 NFPA Classification : 2 Flammable Liquid
 Lower heating value : 11,500 BTU/lb
 NFPA Hazard Rating :
Health : 2
Flammability : 3
Reactivity : 0

3
 Chapter-3

SUPPLY & DISTRIBUTION SYSTEM

3.1 Steps in handling Ethanol :

Ethanol is a by-product at Sugar Industries in our country. Presently, Bureau of Indian Standards under specification
IS:2796:2000 recommends addition of Ethanol in Motor spirit upto 5% volume.

Following are the steps in handling Ethanol:

i) Production of Ethanol at Sugar Industry

ii) Transportation of Ethanol by tank truck to our Terminal / Depot

iii) Unloading of Ethanol at Terminal / Depot

iv) Storage of Ethanol in Tanks at Terminal / Depot

v) Doping of Ethanol in Motor spirit

vi) Transportation of Ethanol mixed Motor Spirit to Retail outlet

vii) Unloading of Ethanol doped Motor Spirit at Retail outlet underground Tank

viii)Delivery of Ethanol doped Motor Spirit to vehicles

Ethanol is categorized under Hazardous Chemical category as a highly inflammable liquid & toxic chemical as per
"Manufacture, Storage and Import of Hazardous Chemical (Amendment) Rules, 2000".

3.2 Production of Ethanol at Sugar industry -

Process & Safety during manufacturing and process is to be taken care of by the Manufacturer as per Statutory/ Regulatory
guidelines.

4
 Chapter-4

STATUTORY LICENSES / APPROVALS

4.1 Statutory approval from Factory Inspector and Pollution Control Board are required for setting up and operating Ethanol
doping facilities.

4.2 Ethanol warrant fulfillment of requirements applicable to Class 'A' petroleum products.

4.3 The distance norms for Ethanol tanks and facilities are made applicable as per OISD-118 applicable for Class 'A' product.

4.4 The layout drawing approval from PESO, Factories Inspectorate shall be obtained before the installation of Ethanol facilities,
since this is additional facility.

4.5 Before commissioning of Ethanol facilities amendment in PESO license is shall be obtained.

5
 Chapter-5

SAFETY DISTANCES FOR ETHANOL TANK

5.1 Distance norms for Above Ground Tank in dyke of Petroleum Product:
Following Safety Distances shall be maintained for Ethanol Above Ground Storage Tanks and Handling Facilites as per
OISD-118, which are as applicable to Class "A" Products, since Flash Point of Ethanol is 13oC.

S. NO EQUIPMENT/FACILITY DISTANCE FROM FACILITY

(IN METERS)
1 Distance of Ethanol Above Ground Storage Tank shell from (D+d)/4 Min. 10 m
Above Ground Storage Tank shell of Class "A"& "B" Product
Tank (All Tanks with Diameter upto 50 Meters)
2 Distance of Ethanol Above Ground Storage Tank shell (D+d)/3 Min.
from Above Ground Storage Tank shell of Class "A"& "B"
Product Tank (All Tanks with Diameter exceeding 50 Meters)
3 Distance of Ethanol Above Ground Storage Tank shell (D+d)/6 Min. 6m
from Above Ground Storage Tank shell of Class "C" Product
Tank (All Tanks with Diameter upto 50 Meters)
4 Distance of Ethanol Above Ground Storage Tank shell from (D+d)/4 Min.
Above Ground Storage Tank shell of Class "C" Tank
(All Tanks with Diameter exceeding 50 Meters)
5 Distance of Ethanol Storage Tank shell from Loading 15 m Min.
Facilities for Products Class "A" & "B".
6 Distance of Ethanol Storage Tank shell from Loading 15 m Min.
Facilities for Product Class "C" .
7 Distance of Ethanol Storage Tank shell from Un-Loading 15 m Min.
Facilities for Petroleum Products Class "A"&"B".
8 Distance of Ethanol Storage Tank shell from 15 m Min.
Un-Loading Facilities for Petroleum Product Class "C".
9 Distance of Ethanol Storage Tank shell from Flame proof 8 m Min.
Electrical Pump,fittings & fixtures.
10 Distance of Ethanol Storage Tank shell from 15 m Min.
Non-Flame proof Electrical Pump,fittings & fixtures.
11 Distance of Ethanol Storage Tank shell from Office 15 m Min.
Building,Stores,Amenities
12 Distance of Ethanol Storage Tank shell from 0.5 D Min.20 m
Boundary Fencing
13 Distance of Ethanol Storage Tank shell from Dyke Wall Min. 0.5 H

Notes: a) All Distances are in meters

b) 'D' & 'd 'stands for Diameter of Larger and smaller tanks.
c) 'H' Stands for height of the tank.
d) All distances shall be measured between the nearest points of each facility except in the case of Tank Truck loading
unloading area where the distance shall be measured from centre of each bay.
5.2 Distance norms for separate dykes:
Separation distance between nearest tanks located in separate dykes shall not be less than the diameter of the larger of the
two tanks or 30 meters, whichever is more.

6
 Chapter-6
SAFETY FITTINGS OF TANK TRUCK
6.1 Safety fittings of Tank Truck :
6.1.1 Engine - Internal combustion engine (Diesel driven) positioned at the front

6.1.2 Exhaust system - Spark arrestor of CCOE approved manufacturer welded at the leak free exhaust muffler or silencer.

6.1.3 Tank design : Tank Truck shall comply with (To be as applicable to Class A product OISD-167 the Motor Vehicle Act,
1988 and Rules framed there under)

6.1.4 The maximum net carrying capacity of tank shall be 97% of its gross carrying capacity.

6.1.5 Registered laden weight (RLW) of vehicle shall not exceed the authorized registered weight of the vehicle.

6.1.6 Maximum width of tank shall be less than width of the cabin tank having a net capacity not exceeding 25000 liter
shall be divided into compartments by liquid-tight partition but not to exceed 5000 liter capacity each compartment.

6.1.7 The Emergency valve shall be of the type fitted with suitable means for preventing development of dangerous static
charge in the TT during bottom loading.

6.1.8 Emergency valve is shall be operated by operating mechanism which is having fusible link.

6.1.9 Fill pipe shall be extended till almost bottom of the compartment having clearance of 25 mm.

6.1.10 The inner end of the fill pipe shall be provided with a splash deflector arrangement (45o angular).

6.1.11 Dip pipe shall have hole of 5 mm dia of holes throughout its length and circumference. The number of holes being
minimum 5 nos in minimum 5 rows. The opening shall be covered with 2 layers of wires gauze having not less than
11 meshes per centimeter.

6.1.12 A datum plate of size 100 mm x 100 mm and thickness not exceeding 5 mm shall be provided exactly below the
dip pipe.

6.1.13 The nominal circuit voltage on the vehicle shall not exceed 24 volts.

6.1.14 All cables shall be armored and protected from mechanical / chemical damages.

6.1.15 To enable electrical circuit to be isolated multipole master switch.

6.1.16 External earthing connector having resistance less than 10 ohms shall be available with TT to be used during
loading / unloading.

6.1.17 Minimum 1x10 kg DCP fire extinguisher and 1 kg CO2 fire extinguisher shall be available with TT.

6.1.18 Tank truck shall be painted as per RTO and other applicable regulations.

6.1.19 The Emergency vent with fusible type to melt at 93oC shall be provided.

6.1.20 Tank truck shall be painted with HAZCHEM label.

7
 Chapter-7

TRANSPORTATION OF ETHANOL

7.1 Safety of Ethanol Tank Truck Loading /Unloading Operation:

7.1.1 TT shall be placed near unloading / loading point by Driver.

7.1.2 Main switch of TT shall be put in 'OFF' position by Driver.

7.1.3 Hand brake of TT to be applied by Driver.

7.1.4 Stopper shall be provided to TT at tyres Front and back by Driver.

7.1.5 1 x 10 kg DCP FE shall be kept at the helpers side of TT at the front by TT Crew.

7.1.6 External earthing shall be connected to TT and earthing point by heavy duty metal clad by Driver.

7.1.7 Splash protective goggles and Nitrile Rubber Hand Gloves to be used by opearator.

7.1.8 Master valves and bottom valves shall be opened and remainder of previously loaded product shall be drained out
in a stainless steel bucket having wire with crocodile clip for bonding with TT valve manifold and then close the
bottom valves by TT Crew.

7.1.9 Nitrile rubber or any other compatible hose shall be used for loading / unloading of Ethanol.

7.1.10 Leak proof coupling made up of Stainless Steel shall be used for Ethanol loading / unloading operation.

7.1.11 All safety precautions shall be taken as that for class 'A' product.

7.1.12 Appropriate recommended dosage of Metal deactivator and corrosion inhibitor shall be added during decantation of
Ethanol from TT into storage tank. So, homogeneity of additives with Ethanol in storage tank can be ensured.

7.1.13 After loading/unloading valves shall be closed, then hose shall be disconnected. Stainless steel bucket shall be used
for collection of leakage or to drain out hose contents.

7.1.14 Put back the 10 kg DCP FE inside the cabin of Tank Truck, remove the stopper, earthing connection and TT can be
moved out by putting on main switch and removing hand brakes.

7.1.15 TT should be loaded/unloaded under supervision.

7.1.16 TT Crew must be present during loading /unloading operation.

8
 Chapter-8

SAFETY OF ETHANOL STORAGE TANKS & HANDLING FACILITIES

8.1 Material of construction:
8.1.1 Ethanol can be stored in above ground (AG) or underground (UG) Tanks.

8.1.2 Tanks fabricated out of Un-plated steel, stainless steel, black iron or bronze can be used for storage of Ethanol since
they have acceptable resistance to corrosion by Ethanol. Avoid use of zinc, brass, copper and aluminum for Ethanol

8.1.3 Non-metallic materials such as Bura-N, Neoprene Rubber, Poly Ethylene, Nitrile, Poly Propylene, Viton and Teflon are
resistible material to Ethanol.

8.1.4 Tank shall be constructed of low carbon, cold finished steel and butt-welded.

Do not use any plated material for the tank.

8.1.5 Epicoating is not recommended for the tanks proposed for storage of Ethanol/ Ethanol doped motor spirit

8.2 Storage Tank Fittings:

8.2.2 The storage tanks fitted with Pressure Vacuum (PV) valve can be used for storing Ethanol after thorough cleaning.
The tank shall be absolutely free from water at all time

8.2.2 Ethanol is hygroscopic and will absorb moisture from air, Silica gel Trap must be provided in the vent pipe of tank
to prevent ingress of moisture into the tank Colour of Silica Gel shall be checked periodically and maintained blue.
Silica gel turns from blue to pink if it absorbs moisture.

Silica gel can be reactivated on heating in an oven for about one hour at 110oC till it again turns blue.

8.2.3 Other opening/pipeline fittings of storage tank shall be air tight and the threaded connections, if any, shall be tight-
ened by using Teflon paste or Teflon tapes. Bolted connections shall have gaskets of Teflon

8.3 Corrosion Inhibitors Recommended for Fuel Grade Ethanol :

CORROSION INHIBITATOR TREAT RATE

ADDITIVE in PTBE ( pounds per thousand barrels of Ethanol)

Octel DCI-11 20

Petrolite Tolad 3222 20

Petrolite Tolad 3224 13

Nalco 5403 30

ENDCOR FE-9730 20
(formerly Betz ACN13)

MidContinental MCC5011E 20

MidContinental MCC5011EW 27

Source: RFA Publication # 960501 Revised December 2003

8.4 Colour coding of Ethanol:

The colour band for ethanol on the pipeline shall be purple. The colour coding shall be in accordance with Clause 4.3.3 of
Industry quality control manual for Non aviation products.

9
 Chapter-9

SAFETY DURING ETHANOL STORAGE TANK CLEANING

9.1 Ethanol Tank cleaning :

9.1.1 Ethanol storage tanks shall be cleaned once in two years or more frequently depending on the need. This is as per
recommendation of "Industrial Manual on Operations, Quality & Safety on Anhydrous Ethanol for use in
Automotive Fuel".

9.1.2 All quantity of ethanol shall be removed from the tank.

9.1.3 Then the tank shall be allowed for de-gassing.

9.1.4 Presence of Ethanol shall be checked by Explosimeter.

9.1.5 If it is free from Explosive mixture, then check the percentage of Oxygen by Oxygen Meter.

9.1.6 If presence of Oxygen is more than 19% you may allow a person to enter into the tank for cleaning by wearing Self
Contain Breathing Apparatus(SCBA).

9.1.7 A Person with SCBA , full body harness, safety shoes, helmet, Reinforced Nitrile Rubber Hand Gloves, Approved
Chemical Goggles, Whistle, Intrinsically safe torch and with rope tightened to his west shall be allowed to go inside
the tank.

9.1.8 At least two persons shall be kept at the manhole to take care of person gone inside holding rope, ready to pull him
out in case of emergency.

9.1.9 Oxygen Apparatus, 2X10 Kg Fire Extinguishers, 4 X 20 Kg ATC Foam, 2 Fire Hoses with 6% Nozzles connected to
Fire Hydrants to be kept ready.

9.1.10 After every 15 Minutes the person who is cleaning the tank shall be replaced by Fresh person.

9.1.11 After every 15 minutes person doing the job of cleaning shall be sent to Fresh Air.

9.1.12 For cleaning the tank chemical absorbent pad/pillows to be used.

9.1.13 After cleaning or in between if tank is idling ; wire mesh shall be provided on manholes so that gas will be come out
and nobody will enter in the tank.

9.1.14 Danger Sign shall be displayed near open manhole.

9.1.15 After completion of cleaning and M&I Inspection and repairing if any, Tank is to be closed by fitting manhole covers.

10
 Chapter-10

DOPING OF ETHANOL IN MOTOR SPIRIT

To ensure uniform doping of Anhydrous Ethanol with Motor Spirit, on line doping shall be carried out through the closed system,
with proper interlocking while maintaining the efficacy of mixing of Ethanol in right proportion of 5% v/v as per specification.

The quantity of Ethanol shall be doped into Motor Spirit shall be worked out compartment wise for the Tank Truck on basis of
5% v/v.

11
 Chapter-11

SAFETY IN DISPENSING OF ETHANOL DOPED MOTOR SPIRIT

11.1 Underground Tanks, Dispensing Unit and Fittings:

11.1.1 Material of construction: Details material and fittings of Storage Tanks are given in the Chapter no.8 (Safety of
Ethanol Storage Tanks). For Dispensing unit also, same criteria is applicable.

11.1.2 Maintenance of Storage Tank Fittings to be carried out as given in Chapter no.8 (Safety of Ethanol Storage Tanks).

11.2 Unloading of Ethanol Doped Tank Truck at Retail Outlet:

11.2.1 Same procedure which is applicable for Unloading of Motor Spirit Tank Truck at Terminal/ Depot is to be adopted at
Retail Outlet. In addition to that, following Health and Safety Measures to be taken .

1. Proper Earthing to be given to Tank Truck before start of Unloading.

2. Dip Hatch of UG Tank to be kept in closed position.

Reinforced Nitrile Rubber Hand Gloves, Approved Chemical splash protective Goggles, Respiratory Protective
Equipment fitted with a combination charcoal or organic vapour cartridge is recommended.

Instead of Aluminum, Stainless Steel Bucket to be used.

11.3 Dispensing of Ethanol Doped Motor Spirit:

11.3.1 Dispensing of Ethanol Doped Motor Spirit is same as Dispensing of Motor Spirit.

11.3.2 First Aid Treatment/ Emergency Procedure to be given depending of the nature of the exposure as given in Chapter
no.15 (Emergency First Aid Procedures).

12
 Chapter-12

ELECTRICAL SAFETY

12.1 Hazardous Area Classification for Ethanol:

12.1.1 Ethanol is classified as Gas II A category. Hence, all Electrical Equipment in the Ethanol Storage and handling areas
must confirm to "Zone-0 & Zone-1" as per requirement of Hazardous Area Classification.

12.1.2 Zone-0 - Means Gas or Vapour is present at all times. An example would be the vapour space above the liquid level
in the top of the product storage tank or drum. No electrical equipment is allowed in this area. If not practicable then
any Instrumentation, measurement, control system or any electrical Equipments shall be Intrinsically safe. Only
"Ex i (ia or ib)" equipment is allowed in the Zone-0 area.

12.1.3 Zone-1-Gas, vapour or mist shall be present or expected to be present for a longer peirod of time under normal
operating conditions. An example would be TLF shed or Ethanol unloading area. Motors, lighting fixtures, Junction
Boxes of Flameproof category shall be provided. The Flameproof electrical equipment of minimum IP54 protective
shall be used in these areas.

12.1.4 Zone-2 - Gas, vapour or mist is not likely to occur in normal operation and if it occurs it shall exist only for a shorter
time. In case of abnormal conditions such as rupture of p/l or tank, leakages thru joints the presence of Gas/vapours
or mist shall take place. An example would be Tank Farm Area.

Motors, lighting fixtures, Junction Boxes of Flameproof category to be provided. The Flameproof electrical equipment
of minimum IP54 protective shall be used in these areas.

12.2 Earthing & Bonding :

During loading/unloading of Ethanol, proper earthing & bonding is to be ensured for dissipation of static charge, if developed
during operation. All hoses used must be periodically tested for electrical continuity. Metal jumper connection to be provided
across two flanges to maintain electrical continuity in the pipeline.

The storage Tank must be earthed in two places.

In addition to earthing of the TT during loading/unloading, additional bonding wire must be connected to TT Manifold to the
loading/unloading valve.

13
 Chapter-13

FIRE AND EXPLOSION HAZARDS, FIRE FIGHTING AND LEAK/

SPILLAGE MANAGEMENT PROCEDURES
13.1 Fire and Explosion hazards :
Ethanol is a highly flammable liquid having flash point of 13oC. Pure Ethanol burns with a flame that is not clearly visible in
bright sunlight. However, ethanol doped motor spirit flame is visible.
Avoid contact with ignition / flame / smoke / hot surface, etc. Avoid contact with acid, oxidizers.
Ethanol is received in sealed Tank Truck. Its storage facilities should be protected against physical damage and the
chemical should be stored away from the Fire Hazards. It shall also be kept away from Oxidizing Agents, Strong Acids like
Surphuric Acid, Nitric Acid etc.
13.2 Fire Fighting Equipment:
Ethanol is not a petroleum product. It is a polar solvent. Hence, normal AFFF will not be able to extinguish a ethanol fire.
Combustion of Ethanol may produce COx , NOx and reactive Hydrocarbons. Hazardous Polymerization will not occur.
DCP, CO2 fire extinguishers can put off a Ethanol fire at the initial stage. Fog is to be dissipated by using Water Spray and ATC
foam have extinguishing effects on it.
Following types of fire fighting/Fog dessipation facilities required for Ethanol.
a) First aid fire fighting facility for small fire or fire at initial stage
b) Fog to be dissipated by using Water Spray
c) Foam facility for fighting fire of bigger intensity
Based on above, following fire fighting equipments and measures are to be taken at the Terminal / Depot where ethanol is
stored and handled
a) First Aid Fire fighting facility:
I. Portable Fire extinguishers:
1. 2 x 10 kg DCP fire extinguishers per tank (AG/UG/Semi-buried tank)
2. 4 x 25 kg DCP fire extinguisher per AG Tank Farm if it is separate from other product T/F or 2x25 Kg for UG
Tank Firm.
3. 1 x 10 kg DCP fire extinguisher for each group of 2 pumps of less than 50 HP
4. 1 x 10 kg DCP fire extinguisher for each pump of 50 HP or more

II. Hose box, hoses, nozzles:

1. Hose boxes : 2 nos
2. Fire hoses : 2 nos (minimum) in each Fire Hose Box
3. Fog Nozzles : 2 No.s
4. Foam making branch pipe for 6% foam induction : 4 nos
Note : These nozzles to be kept segregated from other normal nozzles of AFFF to avoid mix ups during emergency.
All equipments to be provided in 'Purple colour'
b) Foam Facility :
I. Ethanol is a polar solvent and normal AFFF does not have extinguishing effect on it. Hence, ATC foam of 6% concen
tration is used.
II. ATC foam requirement - Ethanol is stored in UG / semi-buried or AG cone roof AG horizontal tanks. Requirement of ATC
foam will be different for different types of storage which is based on NFPA-11.

14
 III. For UG / semi-buried ethanol tank storage - The probability of UG tank fire is almost 'NIL'. However, fire during receipt
of TT at location and doping of ethanol in MS at TLF bay cannot be ruled out. OISD advised to keep minimum 1 KL of
ATC foam at each location (As per OISD-117 Clause no.4.4.12)
IV. For above ground cone roof ethanol tank - ATC foam requirement is calculated @ 6.5 LPM per m2 of burning surface
area in the tank on fire (sample calculations as per Annexure-B)
V. For above ground horizontal ethanol tank - ATC foam requirement is calculated @ 6.5 LPM per m2 of burning surface
area in a tank on fire (sample calculations as per Annexure-C)
13.3 Fire Fighting Procedures:
a) When spot a Fire-
i) Raise alarm by shouting "FIRE-FIRE-FIRE" and activate nearest Fire Siren.
ii) If possible control and extinguish the fire by operating nearest Fire Extinguisher
iii) If it is not possible to extinguish and fire continued, then activate the Fire Siren.
b) Small Fire :
I. Operate DCP Fire Extinguisher immediately to extinguish the fire .
II. Spray water to cool the adjacent area by using Water Monitor/ Fog nozzle.
III. Connect the Fire Hoses to Hydrant Valves and For fog dissipation use Fog nozzles and spray the water.
IV. Keep ready ATC Foam and nozzle for use of 6% Foam, if required.
b) Major Fire Scenarios :
• Tank Fire:
i. Activate the Fire Siren.
ii. Stop the power supply except lighting of Admin Office and Yard Lights and shut down the all the activities of location.
iii. Evacuate the area of all unnecessary personnel.
iv. Close the valves which are in opened condition.
v. Wear suitable protective equipment: SCBA ,Fire Proximity Suit, safety shoes, Reinforced Nitrile Rubber Hand Gloves,
Chemical Splash Goggles etc.
vi. Contain the release and eliminate its sources of product leakage, if this can be done without risk.
vii. Activate the Hydrant Monitors for cooling the Tank on fire and nearby area and cool the shell of tank.
viii. Connect the fire hose and nozzle for 6% ATC Foam and apply it on the Tank on fire or liquid surface on fire or TT on fire
or Product manifold on fire. Continue the operation till the fire is extinguished and possibility of reigniting is nil.
ix. Apply cooling water to other adjoining tanks exposed to heat of fire. Continue till the fire is extinguished and all adjoining
structures is cooled down.
x. For fog dissipation use Fog nozzles and spray the water.
xi. If possible, transfer the product from tank on fire to another tank.
xii. Use Water Gel Blanket for Burn injured persons after removing the victim to safe place
• Tank Truck Fire :
i) Activate the Fire Siren.
ii) Stop the power supply except lighting of Admin Office and Yard Lights and shut down the all the activities of location.
iii) Evacuate the area of all unnecessary personnel and vehicles.
iv) Close the valves which are in opened condition.
v) Wear suitable protective equipment: SCBA, Fire Proximity Suit, safety shoes, Reinforced Nitrile Rubber Hand Gloves,
Chemical Splash Goggles etc.
vi) Contain the release and eliminate its sources of product leakage, if this can be done without risk. Activate the
Hydrant Monitors for cooling the Tank on fire and nearby area and cool the shell of tank.

15
 vii) Connect the fire hose and nozzle for 6% ATC Foam and apply it on the top of the Tank Truck on fire. Continue the
operation till the fire is extinguished possibility of reignition is nil.
viii) Apply cooling water to other adjoining Tank Trucks exposed to heat of fire. Continue the cooling till the fire is extin
guished and area is cooled down.
Ix) Use Water Gel Blanket for Burn injured persons after removing the victim to safe place or use SCBA or Oxygen Apparatus
depending on the situation and requirement.
• Pool Fire :
i) Activate the Fire Siren.
ii) Stop the power supply except lighting of Admin Office and Yard Lights and shut down the all the activities of location.
iii) Evacuate the area of all unnecessary personnel.
iv) Close the valves which are in opened condition.
v) Wear suitable protective equipment: SCBA, Fire Proximity Suit, safety shoes, Reinforced Nitrile Rubber Hand Gloves,
Chemical Splash Goggles etc.
vi) Contain the release and eliminate its sources of product leakage, if this can be done without risk. Activate the Hydrant
Monitors for cooling the Tank on fire and nearby area and cool the shell of tank.
vii) Connect the fire hose and nozzle for 6% ATC Foam and apply it on the top of the Tank Truck on fire. Continue the
operation till the fire is extinguished and cannot reignited.
viii) Apply cooling water to other adjoining Tank Trucks exposed to heat of fire. Cooling to continue till the fire is extin
guished and area is cooled down.
ix) For fog dissipation use Fog nozzles and spray the water to prevent damage to adjacent equipments.
x) Avoid overflowing trenches or pits with water as they may cause spread of fire .
xi) Avoid working on sewer drain manholes or near fire traps.
xii) Use Water Gel Blanket for Burn injured persons after removing the victim to safe place .
13.4 Spill or leak Management procedures:
Steps to be taken in case of Ethanol is released or spilled:
i) Evacuate the area .
ii) Wear suitable protective equipment: SCBA, Fire Proximity Suit, safety shoes, Reinforced Nitrile Rubber Hand Gloves,
Chemical Splash Goggles etc.,
iii) Eliminate any ignition sources until the area is determined to be free from explosion or fire hazards
iv) Contain the release and eliminate its sources, if this can be done without risk.
v) Take up and containerize for proper disposal as described in Chapter No.17 of "Procedures for Disposal of Ethanol
Ethanol doped Motor Spirit"
vi) Use ATC foam as per requirement to cover the spilled product.
vii) Comply with Factories Act, Pollution Control Act and local regulations on reporting releases.

16
 Chapter-14

HEALTH HAZARDS OF ETHANOL AND INDUSTRIAL

HYGIENE & SANITATION
14.1 Health Hazards of Ethanol:
14.1.1 Toxic Dose - LD50 : 7060 mg / kg (oral rat).

14.1.2 Signs and Symptoms of exposures: May cause dizziness, loss of balance and co-ordination.

14.1.3 Health hazards, general : Intoxicating if inhaled or ingested

14.1.4 Inhalation : May cause transient irritation to respiratory system. Exposure to high vapour concentration may cause
central nervous system depression or systematic effects similar to those of ingestion

14.1.5 Ingestion : May cause nausea, vomiting, dizziness and depression of central nervous system. Aspiration during
swallowing or vomiting may severely damage the lungs

14.1.6 Skin : Repeated or prolonged contact may cause irritation and or drying (defatting) of the skin. Anhydrous Ethanol
may cause Skin discolorisation with irritation due to defatting action on Skin. This causes redness, pain, drying and
cracking of skin. Prolonged contact of Ethanol with skin may cause dermatitis.

14.1.7 Eyes : May cause transient eye irritation or damage. Ethanol vapours may cause irritation to eyes and splashes can
cause severe irritation and possible eye damage.

14.1.8 Other Health effects : Adverse effects on male reproductive system on prolonged exposure. Inconsistent
mutagenic activity has been reported.

14.1.9 Excessive exposure may cause mucus membrane irritation, unconsciousness, respiratory failure and death

14.2 Industrial Hygiene and Sanitation:

14.2.1 Good Industrial hygiene practices recommend that Engineering controls be used to reduce environmental concen-
trations to the permissible exposure levels (TLV-1000.0 ppm).

14.2.2 Respirators with a combination of charcoal or organic vapour cartridge is to be used when engineering and work
practice controls are not technically feasible when such controls fails and need to be supplemented.

14.2.3 SCBA will be used for operations which require entry in the tanks or closed vessels and in the emergency situation.

14.2.4 Approved chemical safety goggles to be used during handling of ethanol. Nitrile rubber hand gloves to be used
during handling of ethanol. If skin comes in contact with ethanol, during storage and handling, it should be promptly
washed or showered to remove any ethanol.

14.2.5 Persons handling ethanol should wash their hands thoroughly with soap or mild detergent and water before eating
or using toilet facilities or smoking.

17
 Chapter-15

EMERGENCY FIRST AID PROCEDURES

First Aid facilities for providing immediate first aid in the event of any emergency, should be near the ethanol storage / handling
facilities. Also, arrangement of a physician on call should be made for Emergency treatment in case of somebody getting accidently
over exposed to anhydrous ethanol. The address and telephone nos. of such physicians on call should be properly displayed in
English / Hindi as well as local language in Location In-charge's / Shift In-charge's room.

In the event of an emergency, following first aid procedure to be performed and send for first aid or medical assistance.

15.1 Eye Exposure: If ethanol gets into the eyes, wash eyes immediately with large amount of water for 15 to 20 minutes. Get
medical attention as soon as possible. Contact lenses should not be worn when working with this chemical.

15.2 Skin exposure : If ethanol gets on the skin, promptly flush the contaminated skin with water. If ethanol soaks through the
clothing, remove contaminated clothes immediately and wash affected area with plenty of soap and water. If irritation
persists, seek medical attention.

15.3 Inhalation : If a person inhales a large amount of ethanol, move the exposed person to fresh air. If breathing has stopped,
perform artificial respiration. If recovery not rapid, seek medical attention.

15.4 Ingestion : "DO NOT INDUCE VOMITING IF PERSON IS UNCONSCIOUS". In case of spontaneous vomiting, be sure that
vomit can freely drain because of danger of suffocation. Only when conscious, rinse mouth with plenty of water and give
plenty of water to drink (Approx. 500 ml). Keep patient at rest and obtain medical attention.

15.5 Rescue Procedures : The Rescue team should follow certain safety precautions and use of Personal Protective equipment
to be ensured so that Rescue team members do not get exposed to hazards themselves. Also, the rescue team members
should be trained and fully conversant with the notified Emergency procedures and should know the location of rescue
equipment.

The rescue procedures are as follows:

a) The affected person should be removed from the hazardous area to fresh air

b) Give immediate first aid to the affected person as per requirement and call for medical attention as soon as possible.

c) If the exposed person has become unconscious call the help from other person for removal of affected person to
Hospital for medical attention. Doctor on duty should be called immediately, so that he can reach the site / hospital in
the shortest possible time.

18
 Chapter-16

PERSONAL PROTECTIVE EQUIPMENT (PPE)

16.1 Personal Protective Equipments for Handling Ethanol:

The operating / maintenance personnel must wear the below mentioned personal protective equipment while working in
ethanol storage / handling areas and doping facilities to avoid exposure to Ethanol.

16.1.1. Respirators - For short period of work a suitable Respiratory Protective equipment fitted with a combination
charcoal or organic vapor cartridge is recommended.

16.1.2 Protective Hand gloves - Use impervious gloves made of Reinforced Nitrile Rubber

16.1.3 Eye Protection - Approved chemical Splash goggles or face protection.

16.2 Other Protection - Use engineering controls to reduce air contamination to permissible exposure level. Wear
Personal protective equipment appropriate to the quantity of material handled.

16.3 Hygienic work practices - Skin protection - Apply barrier cream to hands and exposed skin.

16.4 Ethanol leakages / Spills detection and Absorption :

1. Ethanol detector - Portable

2. Sorbent Pads / Pillows - 5 Nos. 4 x 4 & 5 Nos. pillows

16.5 PPEs for Emergency and for Rescue team :

1. 45 minutes duration Self Contained Breathing - 2 nos (Minimum)
Apparatus (SCBA) with spare Air cylinder

2. Protective hand gloves - 2 pairs (Minimum) Nitrile Rubber hand gloves

3. Eye protection - 2 pairs of approved Chemical Splash Goggles or face protections

(Minimum)

4. Safety Helmets - One per Person

5. Resuscitators - 2 Nos.

6. Oxygen Pack - 1 No.

7. Eye wash fountain - 1 No.

8. Water jel blankets - 1 No.

9. Nitrile Rubber Apron - 2 Nos.

10. Fire Proximity Suit - 1 No.

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 Chapter-17

DISPOSAL OF WASTE ETHANOL/ETHANOL DOPED MOTOR SPIRIT

Ethanol/Ethanol doped Motor Spirit shall not be allowed to flow into sewers, where vapour may get ignited. Incineration can be
organized as per rules and regulations. Explore the possibility for resale of contaminated Ethanol to any of the suppliers, who are
in the approved list of Pollution Control Authorities.

Because of Ethanol's affinity for Water, improperly stored Ethanol-blended Motor Spirit contaminated with water can undergo
"phase separation". When phase separation occurs, the Ethanol absorbs excess water until it separates from the Motor Spirit. The
gasoline then floats on top of this Water-Ethanol combination that sits in the bottom of the tank. By this procedure Motor Spirit can
separated from Water-Ethanol.

The main contaminants in Ethanol are water. Purified Ethanol is distilled over into a receiver. Water and all other contaminants are
left behind in the boiler and are removed through a drain after testing.

Solid waste containing Ethanol such as paper, towels, rags etc. are to be disposed of into waste bins. These waste bin should be
away from any ignition source.

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 H,S&E Department, HO
ANNEXURE-A

ETHANOL MATERIAL SAFETY DATA SHEET

(As per Industrial Manual on Operations,
Quality & Safety on Anhydrous Ethanol for Use in Automotive Fuel)

 Chemical formula : C2H5OH

 Mol. Wt. : 46.07

 Appearance and odour : Clear, Colourless, volatile liquid with an ethereal odour

 Octane(R+M)/2 : 98-100

 RON/MON : 108.6/89.7

 Lower heating value BTUs/lb : 11,500

 Reid Vapour pressure (psi) : 2.3

 Ignition Point :

a) Fuel in air percentage : 3-19

b) Temperature (approx. ºC) : 455

 Specific Gravity 15.6º / 15.6ºC : 0.7936

 Boiling point ºC : 78

 Solubility in water @ 21ºC%vol : 100

 Flame visibility : poor

 LEL / UEL : 4.3 / 19

 Flash Point ºC : 13.0

 Cubical expansion Lt./kl/°C : 1.12

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 ANNEXURE-B

TYPICAL EXAMPLE FOR CALCULATION OF ATC FOAM REQUIREMENT

FOR ABOVE GROUND CONE ROOF TANK FOR ETHANOL.

1. DESIGN BASIS:
ATC Foam requirement for Ethanol A.G. Cone Roof Tank on Fire

2. CONE ROOF TANK PROTECTION:

Data:
Dimensions of Tank
Diameter = 10 mtr
Height = 12 mtr

Tank Roof Area = Π d2 = 3.14 x 102 = 78.5 m2

4 4

As per NFPA-11, for Polar Solvent (Ethanol), ATC Foam Solution application is considered at the rate of 6.5 LPM per M2 of burning
surface in the Tank on Fire.

Therefore, ATC foam solution required = 78.5 x 6.5 LPM

= 510.25 lpm = 30.615 KL / hr.

Here 6% ATC foam concentrate is used. Hence, quantity of ATC Foam concentrate required
= 30.615 KL / hr x 0.06 = 1.837 KL / hr.

As per NFPA-11, provision for 65 minutes requirement of Foam concentrate to be kept at location which will be
= (1.837 KL / 60) X65= 1.99 KL = 2.0 KL

22
 ANNEXURE-C

TYPICAL EXAMPLE FOR CALCULATION OF ATC FOAM

REQUIREMENT FOR A.G. ETHANOL HORIZONTAL TANK

1. DESIGN BASIS:

ATC Foam requirement for Ethanol A.G. Horizontal Tank on Fire

2. HORIZONTAL TANK PROTECTION:

Data:

No. of Tanks - 1 AG - 70 KL

Dimensions of Tank

Diameter = 3 mtr

Height = 10 mtr

Since the Tank is placed horizontally, when the tank is half filled then the liquid Surface Area will be maximum. Hence, liquid Surface
Area at the middle = D X L = 3 X 10 = 30 m2

As per NFPA-11, for Polar Solvent (Ethanol), ATC Foam Solution Application is considered at the rate of 6.5 LPM per Sq. Meter of
Liquid Surface of the Tank on Fire.

Therefore, ATC foam solution required= 30 x 6.5 LPM

= 195 lpm = 11.7 KL / hr

Here 6% ATC foam concentrate is used. Hence, quantity of ATC Foam concentrate required = 11.7 m 3 / hr x 0.06
= 0.702 KL / hr.

As per NFPA-11, provision for 65 minutes requirement of Foam concentrate to be kept at location which will be
= (0.702 KL / 60) X65= 0.760 KL

But as per OISD's advice, minimum quantity of ATC Foam to be positioned at location having Ethanol Tankage is 1 KL.

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