PowerPoint Presentation

[Audio] "Standard Operating Procedure. POCL₃ Bubbler Replacement. This video explains the safe method for handling, removing, and installing a POCL ₃ bubbler at the TPREL Bangalore facility in cell production line, ensuring full compliance with safety and chemical control requirements.".

[Audio] "Objective: To safely replace the POCL₃ bubbler while preventing toxic exposure, chemical spills. This procedure ensures proper isolation, controlled handling, and strict compliance with safety protocols.".

[Audio] "This procedure applies to all personnel involved in POCL₃ bubbler replacement. The Production team ensures adherence to Safety control measures specified in JSA & SOP, chemical isolation and confirms that no feeding activity continues. The HSE Officer carry out risk assessment with production team, verifies PPE compliance, safety controls, and emergency preparedness.".

[Audio] "Why this activity is critical: POCL₃ is a highly corrosive and toxic chemical. Its fumes can cause severe respiratory irritation and, in serious cases, may lead to chemical pneumonitis or delayed pulmonary edema. Direct contact with POCL₃ results in painful burns to the skin and eyes, and even brief exposure can cause significant injury. NFPA Health Rating is 4 which means under emergency conditions, it can be lethal. This chemical reacts violently with moisture, releasing heat and generating hydrochloric and phosphoric acid fumes, both of which are extremely hazardous to personnel and equipment. NFPA Rating W - No water: Materials that react violently or explosively with water. There are also major operational risks. Incorrect handling may cause chemical leaks, while overfilled barrels can develop pressure build‑up, increasing the risk of spillage or rupture. Instability Rating is 2 which means it will readily undergo violent chemical changes at elevated temperatures and pressures. Improper isolation of the system can allow corrosive fumes to escape, putting staff at risk and compromising the safety of the entire work area. Because of these risks, strict controls, proper PPE, and adherence to the approved procedure are essential from the very beginning of the POCL₃ bubbler replacement activity.".

[Audio] Preparation and Safety Readiness. Before starting the POCL₃ bubbler replacement, bring the automation system to a complete halt to prevent any unintended motion or chemical feeding. This typically takes about fifty minutes. Verify all guards, interlocks, and access doors, ensuring no personnel are in hazardous zones and that there is no risk of injury. Isolate the tube or row from chemical flow using the approved lockout–tagout procedure, and continue only after confirming zero flow. Ensure that only authorized and trained personnel perform this task, and that no chemical handling occurs without proper approval. Finally, wear all required PPE, including chemical‑resistant gloves, safety goggles, a face shield, and a respirator. These precautions prepare the team for safe continuation of the POCL₃ bubbler replacement process.".

[Audio] "Mandatory PPE for POCL₃ handling includes impervious, chemical‑resistant gloves and chemical safety goggles supported by a full face shield, as recommended in the material safety data sheet. Personnel must wear acid‑resistant protective clothing such as coveralls, aprons, and chemical‑resistant footwear to prevent skin contact. A full‑face respirator with an appropriate cartridge, or a supplied‑air respirator when ventilation is inadequate, is required due to the corrosive and highly irritating fumes of POCL₃. Ensure that emergency showers and eyewash stations are fully accessible before beginning the task.".

[Audio] "Emergency Preparedness. Ensure that a fully stocked first‑aid box is available at the work location, and that a portable fire extinguisher is easily accessible. Confirm that the emergency response plan is understood by all personnel, and clearly communicate the designated safe assembly points before starting the activity. Emergency showers and eyewash stations must be functional and readily accessible, as POCL₃ is highly corrosive and can cause severe injury to the skin and eyes. Self‑contained breathing apparatus or supplied‑air respirators must also be kept ready for emergency rescue due to the respiratory hazards associated with POCL₃ fumes. Ensure adequate ventilation and be prepared to move affected personnel to fresh air immediately in case of inhalation exposure. Finally, all team members must be aware of the evacuation procedure and the conditions under which the emergency alarm must be activated.".

[Audio] "Chemical Barrel Inspection and Handling. Before using the chemical barrel, inspect it thoroughly to confirm that the chemical is in usable condition, the expiry date is valid, and that the barrel is intact, properly labelled, and free from any damage. Also ensure that the barrel is not overfilled. Place the barrel carefully in the designated and approved location, ensuring it is stable and cannot tip over. Keep the chemical barrel closed at all times, except during loading or unloading. Avoid inhaling chemical vapours and make sure the work area is well ventilated throughout the activity.".

[Audio] "Removal of Existing Bubbler. Unseal the chemical barrel only just before loading or unloading, minimizing both exposure and the release of fumes. Carefully unpack the bubbler to be replaced using only the approved tools specified in the POCL₃ bubbler kit checklist. Avoid applying excessive force to prevent damage. Retain and reuse the original packing material, and handle every component gently to avoid breakage or contamination. Disconnect all pipes and fittings connected to the bubbler inside the tube, following the sequence defined in the Job Safety Analysis. Operate knobs and valves slowly and cautiously to prevent sudden chemical release. Unload the empty bubbler carefully and inspect it thoroughly to ensure no chemical residue or leakage is present. Immediately close and secure the empty chemical barrel after unloading to maintain safety and containment.".

[Audio] "Installation of the New Bubbler and Chemical Connection. Begin by positioning the new bubbler correctly and ensuring proper alignment before making any connections. Follow the POCL₃ Bubbler Changing Checklist step by step as you connect all pipes and fittings to maintain accuracy and consistency. Use only approved tools for every connection to prevent damage, improper sealing, or misalignment. Ensure that all fittings are tightened to the specified torque and that every seal is correctly placed to maintain system integrity. Once the loading process is complete, close the chemical barrel immediately to prevent exposure to fumes and maintain a safe working environment.".

[Audio] "System Checks and Restart Preparation. First, verify that all connections have been installed correctly and are secure. Next, check every joint, pipe, and fitting for possible chemical leaks using litmus paper to detect even minor traces. Confirm that all temperature settings and process parameters are within the specified limits, including filling mineral oil in the thermo‑well if required. If you observe any leak or abnormal condition, stop the activity immediately. Inform the supervisor, activate the emergency alarm, and evacuate the plant according to the established emergency procedures.".

[Audio] Repeat the Activity on Both Sides of the Machine. The same procedure must be carried out on both sides of the machine wherever a POCl₃ bubbler is installed. Ensure that every step of the bubbler replacement process — including isolation, unloading, installation, and system checks — is repeated with the same level of safety, accuracy, and control. This guarantees consistent operation and prevents chemical imbalance or process disruption across the system.".

[Audio] "Once the activity has been completed successfully, ensure that all access doors and guards are closed and secured. Seal the chemical barrel properly, apply the required labeling, and store it in the designated safe area. Restore the system only after receiving formal clearance from the supervisor. Finally, maintain proper housekeeping by ensuring the work area is clean, orderly, and completely free of any chemical spills or residues.".

[Audio] TBWS – Team Based Work System- A structured way to plan, implement and review the daily work system through a capable team. Our Safety Mission is to make every task even safer. Thank you for watching — Safety Apne Hawale.