caersafetysummitvto6-14-12updated

7/27/2019 CAERSafetySummitVTO6-14-12Updated

1/14

VACUUMTRUCK

OPERATIONS

CAER Safety Summit

June 2012


2/14

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 SecondaryContainment (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 ANDProposed 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


3/14

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 VaporsPersonal H2S Alarm Actions

Defined and Controlled Offloading


4/14

TRAINING AND AWARENESS

Contract Vacuum Truck Operators must be trained:

API Recommended Practice 2219 forSafe Operation of VacuumTrucks in Petroleum Service

Their Company Specific Vacuum Truck Procedures

Loading, Unloading, Venting, Bonding/Grounding, ContinuityChecks, Scrubbers, etc

HAZWOPER Certified

Workers working with vacuum truck operators (Plant Operators,

Mechanics, Supervisors, etc) must have Awareness training in theprinciples of Safe Vacuum Truck Operations.

Unit Operators must be specifically trained to be familiar with the

Vacuum Truck Checklist and the Offloading Matrix.


5/14

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


6/14

CLEAN TANKS AND VACUUM PUMPS

To Prevent Possible Harmful Chemical Reactions:

The tank and pump must be cleaned after each load, except:

1. When Returning to the Same Location to Load the Same

Material, or

2. 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-HoursCallout.

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.


7/14


8/14

PRODUCT IDENTIFICATION

All Materials Loaded onto a Vacuum Truck must be Positively

Identified.

The Operator or Equipment Owner is Responsible toPositively Identify the Material to be Loaded and the

Properties of the Material.

Flammable or Combustible

H2S or Other Toxic Characteristics

Corrosive Material


9/14

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


10/14

STATIC ELECTRICITY MANAGEMENT

Vacuum Truck Hoses Undergo Continuity Checks and

Scheduled Inspections

Each Time a Vacuum Truck is Loaded the Vacuum Hoseand Grounding Wire are Checked for Electrical Continuity

Plastic Containers Are Not Used to Catch Flammable or

Combustible Liquids


11/14

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


12/14

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 ofWhat 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


13/14

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 toDesignate the Offloading Location According to a Pre-

Identified Offloading Matrix to Ensure Material Compatibility


14/14

Questions

caersafetysummitvto6-14-12updated

Documents