Pamphlet 80 - Edition 4 - August 2014
Pamphlet 80 - Edition 4 - August 2014
Pamphlet 80 - Edition 4 - August 2014
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Table of Contents
1. INTRODUCTION .................................................................................................................................. 1
1.1 SCOPE............................................................................................................................. 1
1.2 CHLORINE INSTITUTE STEWARDSHIP PROGRAM ................................................................ 1
1.3 DEFINITIONS AND ACRONYMS ........................................................................................... 1
1.4 SAFETY PROGRAMS ......................................................................................................... 2
1.5 DISCLAIMER ..................................................................................................................... 2
1.6 APPROVAL ....................................................................................................................... 2
1.7 REVISIONS ....................................................................................................................... 2
1.8 REPRODUCTION ............................................................................................................... 3
2. GENERAL INFORMATION................................................................................................................ 3
2.1 PRODUCT DATA – SODIUM HYDROXIDE AND POTASSIUM HYDROXIDE
SOLUTIONS (CAUSTIC) ..................................................................................................... 3
2.2 CAUSTIC IN TRANSPORTATION .......................................................................................... 3
2.3 REACTIVITY AND COMPATIBILITY DATA .............................................................................. 3
2.4 OTHER HANDLING AND STORAGE CONSIDERATIONS ......................................................... 3
2.5 PERSONAL PROTECTION INFORMATION ............................................................................. 4
2.6 SPILL PREVENTION PROGRAM .......................................................................................... 4
2.7 U.S. ARMY CORPS OF ENGINEERS .................................................................................... 4
3. EMERGENCY RESPONSE ................................................................................................................ 4
3.1 EMERGENCY PLANNING .................................................................................................... 4
3.2 CHEMTREC® AND CANUTEC ......................................................................................... 4
3.3 PROCEDURES FOR SPILLS INTO THE WATER...................................................................... 5
3.4 MARINE INCIDENT REPORTING .......................................................................................... 5
3.5 FIREFIGHTING .................................................................................................................. 5
4. REGULATORY REQUIREMENTS ................................................................................................... 5
4.1 DOT REGULATIONS .......................................................................................................... 6
4.2 MARITIME REGULATIONS .................................................................................................. 6
4.3 EPA REGULATIONS .......................................................................................................... 6
4.4 OSHA REGULATIONS ....................................................................................................... 6
4.5 CANADIAN REGULATIONS.................................................................................................. 7
5. BARGE DESCRIPTION ...................................................................................................................... 7
5.1 GENERAL ......................................................................................................................... 7
5.2 HULLS .............................................................................................................................. 7
5.3 CARGO TANKS, CARGO PIPING, VALVES AND MATERIALS OF CONSTRUCTION .................... 7
5.4 MARKING AND PLACARDING .............................................................................................. 7
5.5 CARGO TRANSFER EMERGENCY SHUTDOWN .................................................................... 8
6. OPERATIONAL STANDARDS ......................................................................................................... 8
6.1 BARGE GENERAL ............................................................................................................. 8
6.2 CARGO SIGNS AND CARGO INFORMATION CARDS .............................................................. 8
6.3 SHIPPING PAPERS ............................................................................................................ 8
6.4 SIGNALS .......................................................................................................................... 8
6.5 SECURING A BARGE TO A DOCK ........................................................................................ 9
7. CAUSTIC TRANSFER - GENERAL INFORMATION .................................................................. 9
7.1 PERSON IN CHARGE ......................................................................................................... 9
7.2 TRANSFER PROCEDURES ................................................................................................. 9
7.3 PRE-TRANSFER INSPECTION ............................................................................................. 9
8. CAUSTIC LOADING OPERATION ................................................................................................ 10
8.1 GENERAL ....................................................................................................................... 10
8.2 PREPARATION FOR LOADING ........................................................................................... 10
8.3 CARGO LINE CONNECTIONS ............................................................................................ 11
8.4 STARTING THE LOADING ................................................................................................. 11
8.5 MONITORING THE LOADING ............................................................................................. 11
8.6 COMPLETION OF THE LOADING ........................................................................................ 11
8.7 SECURING THE PIPING AND CARGO TANKS ...................................................................... 11
8.8 FINAL INSPECTION .......................................................................................................... 12
9. CAUSTIC UNLOADING OPERATION .......................................................................................... 12
9.1 GENERAL ....................................................................................................................... 12
9.2 PREPARATION FOR UNLOADING ...................................................................................... 12
9.3 ENGINE EMERGENCY SHUTDOWN ................................................................................... 13
9.4 CARGO LINE CONNECTIONS ............................................................................................ 13
9.5 STARTING THE UNLOADING ............................................................................................. 13
9.6 MONITORING THE UNLOADING ........................................................................................ 13
9.7 COMPLETION OF THE UNLOADING ................................................................................... 13
9.8 SECURING THE PIPING AND CARGO TANKS ...................................................................... 13
9.9 FINAL INSPECTION .......................................................................................................... 14
10. SERVICE REQUIREMENTS ............................................................................................................ 14
11. INSPECTION AND TESTING REQUIREMENTS ........................................................................ 14
11.1 CERTIFICATE OF INSPECTION/LETTER OF OPERATION ...................................................... 14
11.2 REQUIRED INSPECTIONS AND TESTS ............................................................................... 15
11.3 CERTIFICATE OF FINANCIAL RESPONSIBILITY ................................................................... 16
11.4 VESSEL GENERAL PERMIT .............................................................................................. 16
12. REFERENCES .................................................................................................................................... 16
12.1 INSTITUTE PUBLICATIONS ............................................................................................... 16
12.2 DOT REGULATIONS ........................................................................................................ 17
12.3 U.S. COAST GUARD REGULATIONS ................................................................................. 17
12.4 EPA REGULATIONS ........................................................................................................ 17
12.5 OSHA REGULATIONS ..................................................................................................... 17
12.6 TC REGULATIONS ........................................................................................................... 17
APPENDIX A – DATA SHEET A-1 ......................................................................................................... 19
APPENDIX A – DATA SHEET A-2 ......................................................................................................... 21
APPENDIX B -- SAMPLE CERTIFICATES OF INSPECTION ......................................................... 23
APPENDIX C -- SAMPLE WARNING SIGN ......................................................................................... 25
APPENDIX D -- SAMPLE CARGO INFORMATION CARD .............................................................. 26
APPENDIX E -- DECLARATION OF INSPECTION FOR MARINE TRANSFERS ...................... 27
APPENDIX F -- PAMPHLET 80 CHECKLIST ................................................................................... 29
RECOMMENDED PRACTICES FOR HANDLING SODIUM HYDROXIDE SOLUTION
AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) BARGES 1
1. INTRODUCTION
1.1 SCOPE
This pamphlet provides guidelines, recommended practices and other useful information
for the safe shipping, receiving and handling of sodium hydroxide solution and potassium
hydroxide solution in barges. This pamphlet represents a compendium of Institute
membership experience as of the date of publication.
The Chlorine Institute (CI) exists to support the chlor-alkali industry and serve the public
by fostering continuous improvements to safety and the protection of human health and
the environment connected with the production, distribution and use of chlorine, sodium
and potassium hydroxides, and sodium hypochlorite; and the distribution and use of
hydrogen chloride. This support extends to giving continued attention to the security of
chlorine handling operations.
Institute members are committed to adopting CI’s safety and stewardship initiatives,
including pamphlets, checklists, and incident sharing, that will assist members in
achieving measurable improvement. For more information on the Institute’s stewardship
program, visit CI’s website at www.chlorineinstitute.org.
MARPOL 73/78 The International Convention for the Prevention of Pollution from
Ships 73/78
TC Transport Canada
Every site handling caustic should have an ongoing safety program. Periodic training
sessions and safety inspections must be conducted in accordance with DOT and/or TC
regulations. Special attention should be directed to the appropriateness of emergency
procedures and to equipment to be used in an emergency. Additional information on safety
programs is available from the Institute and from caustic suppliers.
1.5 DISCLAIMER
The information in this pamphlet is drawn from sources believed to be reliable. The Institute
and its members, jointly and severally, make no guarantee, and assume no liability, in
connection with any of this information. Moreover, it should not be assumed that every
acceptable procedure is included, or that special circumstances may not warrant modified
or additional procedures. The user should be aware that changing technology or
regulations may require a change in the recommendations herein. Appropriate steps should
be taken to insure that the information is current when used. These recommendations
should not be confused nor conflict with federal, state, provincial, municipal or insurance
requirements, or with national safety codes.
1.6 APPROVAL
The Institute's Transportation Issue Team approved Edition 4 on August 12, 2014.
1.7 REVISIONS
1.8 REPRODUCTION
The contents of this pamphlet are not to be copied for publication, in whole or in part,
without prior Institute permission.
2. GENERAL INFORMATION
2.1 PRODUCT DATA – SODIUM HYDROXIDE AND POTASSIUM HYDROXIDE SOLUTIONS (CAUSTIC)
Sodium hydroxide solution and potassium hydroxide solution are the proper shipping names
for these products. However, this pamphlet will henceforth use the generic product
name caustic soda to mean sodium hydroxide solution and caustic potash to mean
potassium hydroxide solution and caustic to mean both. Personnel handling caustic
barges should be thoroughly familiar with the chemical and physical properties as well as
the health hazards and first aid procedures appropriate for these products. It is highly
recommended that the reader review Appendix A before continuing. Up- to- date Safety
Data Sheets (SDS) are available from caustic suppliers.
Under normal use and conditions, caustic is generally regarded as stable. However, caustic
will rapidly attack and destroy such materials as leather, wool, pure metals and alloys of
aluminum, zinc and tin. In addition, the reaction with these metals may generate flammable
hydrogen gas. The reaction of caustic with aluminum is particularly vigorous and contact
should be avoided. Shipping caustic in unlined tanks above 120°F (49°C) will result in
significantly higher levels of iron pickup. Shipping above 140°F (60°C) is not
recommended. Both caustic soda and caustic potash are strongly alkaline and may react
violently with acidic materials such as hydrochloric or sulfuric acids. Under certain
conditions the addition of water will cause a violent reaction. These reactions will generate
heat and could cause splattering of the liquid. Neither caustic soda nor caustic potash form
hazardous decomposition products nor contribute to hazardous polymerization.
Caustic is a strong alkali solution. Considerable heat is generated when diluted with
water. Proper handling procedures must be followed to prevent vigorous boiling,
splattering or violent eruption of the diluted solution. ALWAYS ADD CAUSTIC TO
WATER and provide agitation. Caustic will also react vigorously with many organic
chemicals. Due caution is required.
PAMPHLET 80
4
Handling caustic requires adequate personal protective equipment to protect the user
against product hazards. This topic is addressed in the U.S. Coast Guard (USCG)
regulations in 46 CFR151.50-73 (12.2.1). Persons handling caustic should be familiar
with these regulations. Recommendations on personal protection equipment for handling
caustic can also be found in CI Pamphlet 65 (12.1). Safety showers and eye wash facilities
should be located in the immediate work area where caustic is handled. Detailed
requirements for personal protective equipment should be established on a site specific
basis.
All transfer facilities should have a documented spill prevention and containment program
for all hazardous materials. Consideration must be given to the containment of caustic spills
and leaks to comply with applicable federal, state, and local regulations.
Regular reports must be made to the U.S. Army Corps of Engineers (COE) stating dates,
loading locations, cargo quantities and discharge points of all missions. Reporting forms
will be provided by the COE.
3. EMERGENCY RESPONSE
Emergency response plans at transfer facilities should already be in place and operators
in charge of transfer operations should be completely familiar with their local plant
emergency response plans for handling spills and leaks. Copies of the plan should be on
file as required by regulation. Each site should have proper emergency equipment on
hand. Additional guidance regarding emergency plans for chlor-alkali facilities may be
found in CI Pamphlet 64 (12.1).
For transportation-related incidents in the U.S., one should utilize CHEMTREC®, the
Chemical Transportation Emergency Center in Falls Church, VA, as the dispatch
agency. CHEMTREC® operates around the clock--24 hours a day, seven days a week
to receive calls from any point in the United States and Canada at 800-424-9300 (703
527-3887 for all other calls). CHEMTREC® provides immediate advice for those at the
scene of emergencies then promptly contacts the appropriate shipper and others as
required. Registration with CHEMTREC® is provided through the American Chemistry
Council. In Canada, CANUTEC, the Canadian Transport Emergency Centre in Ottawa,
RECOMMENDED PRACTICES FOR HANDLING SODIUM HYDROXIDE SOLUTION
AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) BARGES 5
should be used as the dispatch agency. Their telephone number is 613-996-6666 (Call
collect). CANUTEC is administered by Transport Canada and operates in a manner that
is similar to CHEMTREC®.
All spills into the water must be reported to the proper authority as soon as possible. The
source of the leak should be identified and corrective action taken as quickly as possible.
Any spill of caustic amounting to the EPA reportable quantity of 1000 pounds (454
kilograms) dry-weight basis must be reported to the National Response Center in
Washington, D.C. at 1-800-424-8802. Owners and/or operations of facilities and
transportation equipment are subject to substantial penalty for failure to report spills.
Persons engaged in loading, unloading and transporting of caustic by barge are
encouraged to become familiar with all reporting provisions. It should be noted that
several states have specific reporting procedures in addition to those mentioned above.
In most cases, spills of caustic into the water do not require any cleanup since the
products are soluble in water.
CAUTION: Persons performing cleanup work should wear adequate personal protective
equipment and clothing. Reference is made to CI Pamphlet 65 (12.1).
All marine incidents, even those that do not involve a spill or leak of product, should be
reported to the appropriate responsible party. Specific reporting procedures, as provided
for by shippers, must be followed. Certain incidents must be reported to the USCG on form
CG-2692 in accordance with 46 CFR 4.05 (12.3.2). Where spills or leaks occur,
predetermined emergency response procedures should be implemented.
3.5 FIREFIGHTING
The PIC Facility should be adequately trained in the use of CO2 and dry chemical
portable fire extinguishers.
The PIC Facility should know the steps necessary to report a fire. The fire response
team could be a trained fire brigade in the plant or a local fire department.
4. REGULATORY REQUIREMENTS
The DOT regulates the acceptance and transportation of hazardous materials in the
United States, including the specifications for shipping containers, in Title 49 CFR Parts
171-180 (12.2.3). 49 CFR Part 176 covers particular requirements for carriage by vessel,
with special requirements for barges included in Subpart F. The hazardous materials
regulations also include requirements intended to enhance the security of hazardous
materials in transportation by including a security component in employee training
programs and developing and implementing security plans.
Requirements for barge shipments of hazardous materials in U.S. waters are provided in
two U.S. Government publications, 46 CFR (Shipping) and 33 CFR (Navigation and
Navigable Waters)(12.2). The regulatory agencies with jurisdiction under these laws
include the U.S. Coast Guard U.S. Army Corps of Engineers, Maritime Administration
and St. Lawrence Seaway Development Corporation, both housed under DOT, and the
Federal Maritime Commission.
The U.S. Coast Guard and Canadian Coast Guard regulate the transportation of caustic by
barge. Because these products are hazardous chemicals, it is imperative that personnel
involved in any aspect of handling, packaging and transportation of caustic are
knowledgeable of applicable regulatory requirements. Users of this pamphlet should
obtain current editions of all applicable regulations.
Personnel involved in the transfer operations for caustic should be aware of the
regulatory requirements for spills and other emissions. 40 CFR should be reviewed for
specific federal requirements (12.4).
The OSHA’s occupational safety and health standards are found in Title 29 CFR Part
1910. Title 29 CFR 1910.176 regulates material handling and storage, 29 CFR 1910.120
regulates the emergency response to hazardous substance releases and 29 CFR 1910
Subpart I regulates personal protective equipment (12.5). Other regulations that should
be reviewed include 29 CFR Part 195, Occupational Safety and Health for Shipyards,
and Part 1917, Marine Terminals.
RECOMMENDED PRACTICES FOR HANDLING SODIUM HYDROXIDE SOLUTION
AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) BARGES 7
In Canada, the barge transport of caustic is regulated by the Dangerous Chemicals and
Noxious Liquid Substances Regulations. These regulations incorporate many of the
provisions of the rules for the international shipment of bulk hazardous materials found in
Annex II to MARPOL 73/78 and the IMO Bulk Chemical Code.
5. BARGE DESCRIPTION
5.1 GENERAL
Barges of various configurations carry caustic on the inland waterways. Most of these
barges are of the standard size of 195 feet by 35 feet with varying cargo tank
characteristics. Oceangoing barges can be up to 400 feet in length and include barges
that carry rail tank cars and barges that are part of an integrated tug and barge tow.
5.2 HULLS
All unmanned tank barges that carry a bulk shipment of a liquid hazardous material are
assigned a hull type number of I, II, or III. A type I barge hull affords the greater degree
of protection of the cargo against an uncontrolled release of product. A type III barge
hull provides the lesser degree of protection against an uncontrolled release. A type II
barge hull provides a degree of protection between a type I and type III. The barge hull
type is one of the factors used to determine what hazardous cargos can be carried.
Caustic fits into the barge hull type III category and is typically carried in a barge type II
or a type III hull.
Caustic barge cargo tanks are generally constructed of carbon steel and in some cases
are lined with a suitable lining for product quality. Cargo piping may be stainless steel,
carbon steel or steel that is suitably lined. Caustic piping systems should meet the
appropriate standards presented in CI Pamphlet 94 (12.1). Cargo valves should be
carbon steel, stainless steel or various alloys. Brass or bronze is not recommended.
Aluminum or aluminum alloys should never be used in caustic service.
Marking
The product identification number for caustic is UN 1824 for sodium hydroxide and UN
1814 for potassium hydroxide. Details on marking requirements can be found in 49 CFR
Part 172 Subpart D (12.2.3). The product identification number may be included on the
placard.
Placarding
For any quantity of caustic in a barge, a corrosive placard is required. Placards alert
persons to the potential dangers associated with hazardous materials contained within
the barge. Placards also guide emergency personnel who respond to incidents involving
hazardous materials. Details on placarding requirements can be found in 49 CFR Part
172 Subpart F (14.2.1).
PAMPHLET 80
8
There must be a means to stop the flow of caustic in case of an emergency during the
transfer of caustic to or from a marine facility. For the loading of caustic barges, the
emergency shutdown will be activated on shore by the PIC Facility. For caustic
unloading operations, the emergency shutdown will be located on the barge and will be
activated by the PIC Vessel. If the barge's discharge pump is powered by a diesel
engine, there must be a remote engine emergency shutdown that can be activated away
from the engine at approximately the mid-barge position.
6. OPERATIONAL STANDARDS
Bilges and void spaces of caustic barges should be kept substantially free of water. At
every product transfer inspections should be made to ensure all void spaces are kept in
a water-free condition. Cargo tank and void space hatches should be kept closed at all
times except under the supervision of the PIC Vessel.
Warning signs must be displayed on the barge, port and starboard, facing outboard without
obstructions. The warning signs must include the words "Dangerous Cargo, No Visitors,"
and must indicate caustic soda or caustic potash is being carried (46 CFR 35.30-1 –
Warning, No Open Lights, No Smoking, No Visitors with Product Being Carried).
Regulations should be referenced for an exact description of the warning signs.
Appendix C shows a sample warning sign.
A cargo information card must be carried on the bridge or in the pilot house of the towing
vessel. This card must also be carried aboard the barge mounted near the warning sign.
The card must be laminated in clear plastic or otherwise made weatherproof. The cargo
information cards must include characteristics and hazards of the cargo and procedures
to be followed in an emergency. Regulations should be referenced for an exact
description of cargo information cards. Appendix D shows a sample caustic cargo
information card.
Each barge carrying caustic must have shipping papers in the form of either a bill of
lading, cargo manifest or a shipping document that gives the name of shipper, location of
the loading point, and the approximate quantity of caustic on the barge. The shipping
papers should be made out by the shipper. Because caustic barges are unmanned, the
master of the towing vessel is responsible for ensuring the information from the shipping
papers is available. The master of the towing vessel must either have a copy of the
shipping papers or make an entry in the towing vessel's log book giving the name of
shipper, location of the loading point, and the approximate quantity of caustic on the
barge. The barge should not be delayed to secure exact quantities of cargo.
6.4 SIGNALS
While moored to a dock, a barge must display a red flag during the day and a red light at
night while transferring caustic. The signal must be placed so that it is visible on all sides
of the barge. The red flag may be metallic. Depending upon particular local navigation
RECOMMENDED PRACTICES FOR HANDLING SODIUM HYDROXIDE SOLUTION
AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) BARGES 9
rules, different waterways require white lights to be positioned on each outboard corner
of barges that are fleeted or moored at a dock. The local Coast Guard can advise of any
particular rules which apply.
With the assistance of the towing vessel, the barge should be spotted at the dock with
care for proper alignment with the loading headers. These requirements will vary at each
facility depending on the dock configuration. In the event of rough weather, extra lines
and precautions are advisable to safely secure the barge. Barges must be tied off with a
minimum of two lines, one heading forward and one heading aft. The lines should be
continuously monitored during loading and unloading operations and at times when
water levels are changing.
Because cargo tank configuration and valving is different on many barges, it is important
that the PIC Vessel become familiar with the barge's piping arrangement prior to starting
the transfer. A thorough review of the transfer procedures and line diagram should be
made prior to each transfer.
An individual on the barge must be designated as PIC Vessel during transfer operations.
The PIC Vessel must have sufficient training and experience with the vessel and with the
caustic cargo. The PIC Vessel on a U.S. barge must hold a USCG issued merchant
mariner's document which is endorsed, Tankerman-PIC (Barge) Dangerous Liquid (DL)
Cargoes, to permit the holder to serve as the PIC Vessel.
All barges transporting caustic must have written procedures that describe the
particulars of transferring caustic to and from the barge or between tanks on the barge.
Transfer procedures should include a description of the barge's transfer system, a line
diagram of the vessel's piping system, procedures for operating the emergency
shutdown of the caustic transfer, and procedures for reporting caustic spills. The transfer
procedures must be posted or available at a place where they can be easily seen by
persons on the vessel engaged in transfer operations.
Prior to transferring cargo to or from a barge, several items should be checked including,
but not limited to, the following:
All official documents including the COI and the cargo transfer procedures.
All bow, stern, port and starboard void spaces for the presence of water.
Water found in any void space should be reported to the proper authority.
Before pumping void spaces, care should be taken not to pump any oil or
other pollutants into the water. Only approved disposal facilities should be
allowed to pump contaminated water from the void spaces.
PAMPHLET 80
10
The hull for unusual damages which would prevent loading. Damages should
be reported to the proper authority.
All cargo piping, pumps and valves and connections for damage or sign of
possible cargo leakage.
All signs, markings, and stenciling including draft marks, barge name and
hailing port for compliance with applicable regulations.
Mooring lines to ensure they are strong enough to hold during all expected
conditions of surge, current and weather, and are long enough to allow for
adjustments for changes in draft and tidal conditions.
Adequate lighting.
8.1 GENERAL
Personal safety is of utmost importance when loading caustic barges. Gloves, boots,
and an apron or chemical protective suit that are chemically resistant to caustic, and a
hard hat and chemical splash goggles should be worn while connecting the loading line,
transferring cargo, disconnecting the loading line and sampling the cargo tanks. A full-
face shield can also be utilized as added protection. An approved personal flotation
device should be worn at all times while on the barge except when working inside areas
protected by handrails, where the personal flotation device may be removed to facilitate
movement. All established marine facility safety procedures should be followed.
Additional information can be found in CI Pamphlet 65 (12.1).
Prior to beginning the transfer, the PIC Vessel should conduct a pre-transfer inspection.
Draft readings should be recorded. A Declaration of Inspection must be executed and
signed by both the PIC Vessel and PIC Facility according to USCG regulations if in U.S.
RECOMMENDED PRACTICES FOR HANDLING SODIUM HYDROXIDE SOLUTION
AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) BARGES 11
waters. A copy of the signed document must be maintained on file or on board for a
period of one month from the date of signature. Appendix E is an example of a
Declaration of Inspection. The PIC Vessel and PIC Facility should hold a pre-loading
conference before the barge is ready to receive product (33 CFR 156.120(w) and (x)).
In most cases, barges loaded with caustic utilize dedicated tanks to preserve quality of
the delivered product. Care should be exercised to ensure that the previously carried
cargo does not affect the quality of the cargo to be loaded. If there is an appreciable
amount of previously carried caustic cargo or if the previously carried caustic is
discolored, it is recommended that samples of it be taken and analyzed prior to loading.
The proper loading hose from the loading arm or header on shore should be attached to
the correct loading header on the barge. A properly sized drip pan must be placed
beneath each flanged hose connection. All flange bolt holes must be secured with
properly sized bolts during transfer of cargo. The shoreside valve should remain closed
until the proper valves on the barge are opened to receive cargo.
The PIC Vessel should notify the PIC Facility when the barge is ready to receive
product. The dockside valve should be opened slowly to start the flow into the barge. A
physical check should be made to ensure product is flowing into the designated cargo
tank.
Close attention must be paid to the entire transfer. Cargo transfer piping and associated
hoses should be examined routinely to check for leaks, and all mooring lines must be
adjusted as appropriate to ensure the barge remains safely berthed. Adequate cargo
venting should be ensured during the entire transfer to avoid cargo tank damage. The
barge should be kept on an even trim with minimum list to maintain proper control of the
loading. As loading progresses, the void spaces should be monitored. If water begins to
enter a void space during loading, the transfer should be suspended until corrective
actions are taken. It may be necessary to off-load the cargo in order to make repairs.
The most critical period in loading a barge is "topping-off." During the final minutes of the
loading, the operation must be under constant surveillance in order to prevent overflow
on the barge causing a spill in the water. As the loading nears completion, the flow rate
should be reduced by throttling the appropriate valve. When the desired amount of
product is loaded, the transfer operation should be secured. It is suggested that, after
loading, the temperature of each tank be taken and that samples be taken and retained.
When the loading is complete, the residual product in the cargo hose should be
displaced either into a barge cargo tank or back to the marine facility. The detailed
procedure may differ for individual barges but the usual practice is to drain the product
into the barge cargo tanks. A review of the barge's transfer procedure and line diagram
will help determine the proper method. Cargo hoses should be disconnected with care to
ensure all hose drippings are collected in the proper manner. Hoses should be properly
PAMPHLET 80
12
stored in a place designated by the facility. Blind flanges must be installed on both the
barge and shoreside connections with properly sized bolts. All safety equipment should
be utilized when disconnecting hoses. Draining the above deck piping after loading
caustic soda is particularly important because of caustic soda's high freezing
temperature. Caustic potash does not usually present a freezing problem because of its
low freezing point. To prevent tampering, all the cargo tank valves should be closed and
preferably secured with an appropriate seal. All cargo tank and void space hatch covers
should be properly secured.
A final inspection should be made to ensure the cargo tanks are properly marked, cargo
manifest or shipping documents properly stored, cargo identification tags applied to the
applicable valves, and cargo information cards are properly displayed (including cards
for the towing vessel). Shoreside loading equipment that may have been placed aboard
should be removed before the barge is released. For barges equipped with steam coils,
it is advisable to air blow the coils free of water to remove condensate and avoid frozen
or blocked steam lines. All maintenance problems should be reported to the proper
authority for corrective action. A written format is advisable for follow-up and
recordkeeping. Before the barge departs it is advisable to check the proper operation of
the diesel engine that powers the cargo pumps. This will ensure the pump will be
available to off-load cargo in an emergency.
9.1 GENERAL
The steps for unloading caustic barges are essentially the same as for loading but can
be significantly different in regards to operating procedures. Personal safety is of utmost
importance when unloading caustic barges. Gloves, boots, and an apron or chemical
protective suit that are chemically resistant to caustic, and a hard hat and chemical
splash goggles should be worn while connecting the unloading line, transferring cargo,
disconnecting the unloading line and sampling the cargo tanks. A full-face shield can
also be utilized as added protection. An approved personal flotation device should be
worn at all times while on the barge except when working inside areas protected by
handrails, where the personal flotation device may be removed to facilitate movement.
All established marine facility safety procedures should be followed. Additional
information can be found in CI Pamphlet 65 (12.1).
Prior to starting cargo unloading, the PIC Vessel should conduct a pre-transfer
inspection. Draft readings should be recorded. The PIC Facility must ensure that a
Declaration of Inspection is executed and signed by both the PIC Vessel and PIC Facility
according to USCG regulations if in U.S. waters. A copy of the signed document must
be maintained on File or on board for a period of one month from the date of signature.
Appendix E is an example of a Declaration of Inspection.
RECOMMENDED PRACTICES FOR HANDLING SODIUM HYDROXIDE SOLUTION
AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) BARGES 13
Prior to transfer, the emergency shutdown system should be tested to ensure its
readiness. The emergency shutdown must be tested prior to unloading cargo. If a
diesel engine is used to power the cargo pumps, it should be started and the emergency
shutdown activated to ensure the engine will shut down. If a problem is noted with the
above operation, the proper authority should be notified.
The proper unloading hose from the unloading arm or header on shore should be
attached to the correct unloading header on the barge. A properly sized drip pan must
be placed beneath each flanged hose connection. Flanges must be secured with
properly sized bolts during transfer of cargo. The valves on the barge should remain
closed until the proper shoreside valves are opened to receive cargo.
The PIC Facility should notify the PIC Vessel and hold a pre-unloading conference when
the marine facility is ready to receive product (33 CFR 156.120(w) and (x)). The PIC
Vessel should ensure that product is being transferred by monitoring the level in the
barge cargo tanks.
Close attention should be paid to the entire transfer. Since barges can be different in
size and cargo tank configuration, care should be exercised to ensure the transfer is
being accomplished properly in order to successfully remove all the cargo. Cargo
transfer piping and associated hoses should be examined routinely to check for leaks,
and all mooring lines must be adjusted as appropriate to ensure the barge remains
safely berthed. Adequate cargo venting should be ensured during the entire transfer to
avoid cargo tank damage.
It is very important that the transfer be closely monitored whenever the unloading of a
cargo tank nears completion. Reducing the speed of the pump engine (if equipped) and
throttling the discharge valve to slow the unloading is very important to accomplish
complete stripping of the cargo tank. Constant communication between the PIC Facility
and the PIC Vessel is of utmost importance when completing a transfer so appropriate
shoreside and barge valves and the cargo pump can be secured as soon as the transfer
is complete.
When the unloading is complete, the residual product in the cargo hose should be
displaced either into a barge cargo tank or to the marine facility. The detailed procedure
may differ for individual barges, but the usual practice is to drain the product into the
barge cargo tanks. Cargo hoses should be disconnected with care to ensure all hose
drippings are collected in the proper manner. Hoses should be properly blanked and
stored. Blind flanges must be installed on both the barge and shoreside connections with
properly sized bolts.
PAMPHLET 80
14
All safety equipment should be utilized when disconnecting hoses. Draining the above
deck piping after unloading caustic soda is particularly important because of caustic
soda's high freezing temperature. Caustic potash does not usually present a freezing
problem because of its low freezing point.
A final inspection should be made to ensure the barge is ready for release. All cargo
tank and void space hatch covers should be secured. Any shoreside equipment that
may have been placed aboard should be removed. For barges with steam coils, it is
advisable to air blow the coils free of water to remove condensate and avoid frozen or
blocked steam lines. All maintenance problems should be reported to the proper
authority for corrective action. A written format is advisable for follow-up and
recordkeeping.
The PIC Facility must be designated by the facility operator, have at least 48 hours of
transfer operations experience at the facility, know the hazards of the product, and
understand the vessel, facility transfer and operating procedure systems. The PIC
Facility must know the procedures for reporting a discharge and be familiar with the
facilities contingency plan for discharge reporting and containment. The PIC Vessel
must have sufficient training experience with the characteristics of the vessel that pertain
to cargo transfer and handling. This includes the vessel's cargo transfer procedures,
shipboard emergency equipment, the cargo system and procedures for reporting and
responding to spills and pollution incidents.
The PIC Vessel on a U.S. vessel must hold a USCG issued Merchant Mariner's
Document that has been endorsed as a "Tankerman-PIC" or "Tankerman-PIC (Barge)"
authorizing the supervision of the transfer of caustic. On a foreign vessel in U.S. waters,
the PIC Vessel must hold a Dangerous-Cargo Endorsement or Certificate issued by the
flag state attesting the individual meets a standard equivalent to that required on U.S.
vessels.
Note: In 46 CFR 13.303, one of the eligibility requirements for Tankerman-PIC (Barge) is
the participation in at least ten transfers including at least five loadings and five
discharges. However, as stated in the preamble of the final rule (62 FR 25122 - CGD
79-116), a restrictive Merchant Mariner's Document endorsement can be issued to
individuals who cannot get both loading and unloading experience because their facility
is limited to either loading or unloading operations.
For caustic to be carried in a Canadian barge, the barge must be inspected by the
Canadian Coast Guard and issued a Letter of Operation. For caustic to be carried in a
U.S. barge, the barge must be inspected by the USCG and issued a Certificate of
Inspection (COI). The COI contains information that is important in the operation of the
barge including the limiting draft for the barge, the maximum cargo weight for each cargo
tank and the maximum cargo density. Appendix B is an example of a COI.
RECOMMENDED PRACTICES FOR HANDLING SODIUM HYDROXIDE SOLUTION
AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) BARGES 15
The following summarizes some of the inspection requirements for U.S. caustic barges.
The inspection requirements for Canadian barges are similar to those for U.S. barges.
A USCG issued Certificate of Inspection (COI) that specifically authorizes the carriage of
caustic is required for a U.S. tank barge to carry caustic. A COI is issued after the
satisfactory completion of an inspection by the USCG called the "inspection for
certification." This inspection is completed every five years, can be done afloat or while
vessel is on dry dock, and can be done in an empty or loaded condition. However, best
practice is to perform the COI in an empty condition. Once an inspection for certification
has begun, all previously issued COI's are invalid.
Following the inspection, the USCG will issue a temporary COI, valid for up to one year,
which will serve as the vessel's COI until a permanent COI is issued by the USCG. The
temporary COI should be kept aboard the barge until the permanent COI is received.
The permanent COI must be placed aboard the barge in place of the temporary
certificate. Prior to shipping a barge, the presence of the COI must be verified and
checked to ensure all information is current and valid.
An annual inspection must be completed every year within three months before or after
each anniversary of the issuance date of the COI except that either the second or third
annual inspection is replaced by a periodic inspection. Generally, a periodic inspection
is a more in-depth inspection than an annual inspection. The USCG will endorse the
COI or issue an amended COI after an annual or periodic inspection is complete.
A caustic barge operating in fresh water at least six months in every twelve-month period
must be dry docked once every ten years. Barges operating in salt water must be dry
docked once every five years. This is based on a double hull construction having
externally framed cargo tanks that can be examined externally from voids, double
bottoms or other similar spaces. Single hull tank barges are required to be dry docked
twice within a five year period with no interval to exceed three years when operating in
salt water and once every five years when operating in fresh water at least six months
per year. The USCG must be given notice when any caustic barge is placed on dry dock
for any reason.
If the structural framing is on the internal tank surface, the cargo tanks of a caustic barge
must be inspected internally by the USCG once every five years. If the structural
framing is on the external tank surface accessible for examination from voids,
cofferdams, double bottoms and other similar spaces, the cargo tanks must be inspected
internally by the USCG once every ten years.
Barge discharge piping and hoses must be pressure tested annually, according to
provisions in 33 and 46 CFR.
PAMPHLET 80
16
The COFR is a document issued by the USCG that verifies the vessel operator has
satisfied the financial requirements to meet the potential liability for a hazardous cargo
spill. The important item to check on the document is the expiration date. This document
is issued every three years. Although the document is not required to be on the vessel,
the COFR may be downloaded from the USCG’s website
(http://www.uscg.mil/npfc/COFRs/default.asp) and maintained on the vessel for review, if
your company wishes.
The Vessel General Permit (VGP) is a part of the EPA’s National Pollution Discharge
Elimination System (NPDES) (40 CFR Part 122). In general, vessels which operate in
waters of the United States and which have incidental discharges of ballast water, deck
washdown water, etc., must operate under a VGP as covered under the Clean Water
Act (33 U.S.C. 1251)
The Vessel General Permit requires that owners/operators of certain vessels which
operate in the waters of the United States which have incidental discharges of ballast
water, deck washdown water, etc. must fulfill the following requirements:
Submission of a Notice of Intent (NOI)
Submission of a Notice of Termination (NOT)
Routine Visual Inspections, Annual Inspections and Extended Unmanned
Period (EUP) Inspections
Annual Reporting
Non-Compliance Reporting
Corrective Action Process for Permit Violations
12. REFERENCES
The following publications are specifically referenced in CI Pamphlet 80. The latest
editions of CI publications may be obtained at http://www.chlorineinstitute.org.
Pamphlet # Title
12.2.2 Code of Federal Regulations. Title 33. Parts 151-159. Office of the Federal Register
National Archives and Records Administration. U.S. Government Printing Office:
Washington, DC, (revised annually).
12.2.3 Code of Federal Regulations. Title 49. Parts 100-185. Office of the Federal Register
National Archives and Records Administration. U.S. Government Printing Office:
Washington, DC, (revised annually).
12.3.1 Code of Federal Regulations. Title 33. Parts 1-199. Office of the Federal Register
National Archives and Records Administration. U.S. Government Printing Office:
Washington, DC, (revised annually).
12.3.2 Code of Federal Regulations. Title 46. Parts 1-199. Office of the Federal Register
National Archives and Records Administration. U.S. Government Printing Office:
Washington, DC, (revised annually).
12.4.1 Code of Federal Regulations. Title 40. Subchapter D. Office of the Federal Register
National Archives and Records Administration. U.S. Government Printing Office:
Washington, DC, (revised annually).
12.5.1 Code of Federal Regulations. Title 29. Part 1910, 1915 and 1917. Office of the Federal
Register National Archives and Records Administration. U.S. Government Printing
Office: Washington, DC, (revised annually).
12.6 TC REGULATIONS
12.6.1 Guide to Canadian Transportation of Dangerous Goods Act and Regulations, mini version;
ICC International Compliance Center Ltd: Mississauga, Ontario, 1999.
12.6.2 The Dangerous Chemicals and Noxious Liquid Substances Regulations; Transport
Canada (http://www.tc.gc.ca/Actsregs/csa-lmmc/csa12.html)
PAMPHLET 80
18
For further assistance and information on items referenced, contact the following organizations:
PHYSICAL DATA:
Boiling Point: 293°F (145°C) – 50% solution Vapor Pressure: NA
371°F (189°C) – 75% solution
Solution in Water: 100% Vapor Density: 2.49 @ 32°F (0°C) - 50% solution
N/A – 73% solution
Sp. Gravity: 1.52 – 50% solution Appearance: Colorless or slightly colored, clear
1.71 – 73% solution or opaque
Odor: Odorless
Fire and Explosion Hazards: In water solution caustic can react with
amphoteric metals (such as aluminum)
generating hydrogen which is flammable and/or
explosive when ignited.
REACTIVITY DATA:
Stability: Product absorbs water and carbon dioxide from the air.
INCOMPATIBILITY:
Hazardous Material Decomposition: Dilution with water evolves large amount of heat.
Product is strong caustic alkali. May react
violently with acid and a number of organic
compounds. Caustic reacts rapidly with
aluminum, tin, and zinc. It will also react with
bronze and brass.
HEALTH HAZARDS:
Eye: May cause severe irritation with corneal injury
and result in permanent impairment of vision,
even blindness. Dusts may irritate eyes.
ADDITIONAL INFORMATION:
Special Precautions to be Taken in Handling and Storage:
Avoid storing next to strong acids. Caustic should be stored in clean, dry areas. Do not store in
underground tanks. Product absorbs water and CO2 from air. Keep containers closed and
sealed.
The water should be lukewarm (80-100°F)(27-38°C). NEVER start with hot or cold water.
The addition of caustic soda to liquid will cause a rise in temperature. If caustic soda becomes
concentrated in one area, or is added too rapidly, or is added to hot or cold liquid, a rapid
temperature increase can result in DANGEROUS mists or boiling or spattering which may cause
immediate VIOLENT ERUPTION.
RECOMMENDED PRACTICES FOR HANDLING SODIUM HYDROXIDE SOLUTION
AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) BARGES 21
PHYSICAL DATA:
Boiling Point: 271°F (133°C) - 45% solution Vapor Pressure: NA
289°F (143°C) – 50% solution
Odor: Odorless
REACTIVITY DATA:
Stability: Under normal conditions, the material is stable
INCOMPATIBILITY:
Hazardous Material Decomposition: Avoid direct contact with water. This
product may be added slowly to water or
acids with dilution and agitation to avoid a
violent exothermic reaction. Avoid contact
with aluminum, tin, zinc, and alloys
containing these metals. Avoid contact with
leather, organic halogen compounds,
organic nitre compounds, acid and wool.
HEALTH HAZARDS:
Eye: Is destructive to eye tissues on contact. Will
cause severe burns that result in damage to
the eyes and even blindness.
ADDITIONAL INFORMATION:
Special Precautions to be Taken in Handling and Storage:
Avoid storing next to strong acids. Caustic should be stored in clean, dry areas. Do not
store in underground tanks. Product absorbs water and CO2 from air. Keep containers
closed and sealed.
The water should be lukewarm (80-100°F)(27-38°C). NEVER start with hot or cold water.
The addition of caustic potash to liquid will cause a rise in temperature. If caustic potash
becomes concentrated in one area, or is added too rapidly, or is added to hot or cold liquid, a
rapid temperature increase can result in DANGEROUS mists or boiling or spattering which
may cause immediate VIOLENT ERUPTION.
RECOMMENDED PRACTICES FOR HANDLING SODIUM HYDROXIDE SOLUTION
AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) BARGES 23
Each line item is to be checked and initialed by the PIC Vessel and the PIC Facility. A
signed copy must be available for review during transfer. Retain a copy at facility at least
one month from signature date. (Note: When shift changes during a transfer, new shift must
initial each item on this Declaration of Inspection as proof that items were reinspected.
P-I-C P-I-C
FACILITY VESSEL
33 CFR 156.120 – Requirements for Transfer:
(a) Moorings good, strong and with enough line for
adjustment. _______ _______
(b) Transfer hoses long enough to allow vessel to move to
limits of mooring. _______ _______
(c) Hoses supported to prevent kinking, strain on coupling. _______ _______
(d) Each part of the transfer system is aligned to allow
flow. _______ _______
(e) Each part of transfer system not in use is securely
blanked or shut off. _______ _______
(f) Each end of hose and loading arm not connected is
blanked off with adequate closures. (Blind flanges,
butterfly valves, water resilient seated valves, etc.). _______ _______
(g) The transfer system is attached to a fixed connection
on the vessel and the facility except when receiving
fuel, an auto back-pressure nozzle may be used. _______ _______
(h) Sea suction connected to cargo tank system, if
applicable. _______ _______
(i) Transfer hoses in good shape. _______ _______
(j) Loading arms meet 154.500 and 154.110, as
applicable. _______ _______
(k) Connections meet 156.130 – bolt in every hole.
Bolts in good condition, fully and uniformly applied. _______ _______
(l) Monitoring devices in place if required by 154.525. _______ _______
(m) Discharge containment required by 154.545 accessible
of deployed as applicable. _______ _______
(n) Discharge containment required by 154.530, 155.310,
and 155.320 in place and drained to provide capacity
(two barrel containment capacity under each hose
connection). _______ _______
(o) Drain and Scupper Closure as applicable. _______ _______
(p) All connections are leak free except that a component
such as a packing gland may leak at a rate that does
not exceed capacity of discharge containment
equipment. _______ _______
(q) Communications required by 154.560 and 155.785 are
operable. (Continuous voice communications
available.) _______ _______
(r) Emergency means of shutdown required by 154.550
and 155.780 are in position and are operable. _______ _______
(s) There is a person in charge on the transferring vessel
or facility and receiving vessel or facility (Except as
otherwise authorized under 156.115.) _______ _______
PAMPHLET 80
28
P-I-C P-I-C
FACILITY VESSEL
(t) Each person in charge: is at the site of the transfer
operation and immediately available to transfer
personnel. Has in his/her possession a copy of the
facility manual or vessel transfer procedures as
appropriate.
Conducts transfer in accordance with the manual or
procedures. _______ _______
(u) Personnel required under the facility operations
manual: (1) are on duty and (2) conduct transfer in
accordance with facility manual or vessel transfer
procedure. _______ _______
(v) At least one person is at the site who speaks language
of person in charge _______ _______
(w) Person in charge on vessel and facility have held a
conference to understand: _______ _______
(1) Product to be transferred. _______ _______
(2) Sequence of transfer operation. _______ _______
(3) Transfer rate
(4) Name or title and location of each person _______ _______
participating in the transfer. _______ _______
(5) Details of the transfer and receiving system. _______ _______
(6) Critical stages of the transfer operation.
(7) Federal, state, and local rules that apply. _______ _______
(8) Emergency procedures. _______ _______
(9) Discharge containment procedures. _______ _______
(10) Discharge reporting procedures. _______ _______
(11) Watch or shift arrangement. _______ _______
(12) Transfer shutdown procedures. _______ _______
(x) Persons in charge agree to begin transfer. _______ _______
(y) Between sunset and sunrise, adequate lighting is in
place as required by 154.570 and 155.790. _______ _______
(z) Vapor recovery requirements, as applicable. _______ _______
(aa) No hazardous materials on shore barge or barge such
as gasoline or other fuels. _______ _______
(bb) Fire extinguishers set out. _______ _______
Title Title
RECOMMENDED PRACTICES FOR HANDLING SODIUM HYDROXIDE SOLUTION
AND POTASSIUM HYDROXIDE SOLUTION (CAUSTIC) BARGES 29
This checklist is designed to emphasize major topics for someone who has already read
and understood the pamphlet. Taking recommendations from this list without understanding
related topics can lead to inappropriate conclusions.
11. Are procedures in place to secure the piping and cargo {8.7, 9.8}
tanks after transfer is complete?
12. Are the PIC Vessel and PIC Facility properly trained? {11.1}
REMINDER