Workers exposed to uncontrolled hazardous chemical leak (15 February 2024)

Numerous workers at a bulk liquid storage terminal provider were exposed to the uncontrolled gas release of BTX vapours over several days. BTX is a chemical mixture of benzene, toluene and xylene, and is a known carcinogen. Exposure to BTX may result in serious illness or death. The site was evacuated, and emergency services attended the site to control the leak.

Bulk storage tank with corrosion showing location of leak adjacent to the walkway.
Bulk storage tank with corrosion showing location of leak adjacent to the walkway.

Safety information

For information regarding safe use, handling and storage of hazardous chemicals always refer to the Safety Data Sheet (SDS) which must be provided by the manufacturer or importer of the product.

Under Work Health and Safety (WHS) regulations, duty holders must follow the hierarchy of control so far as ‘reasonably practicable’. This means implementing control measures from the highest level of protection and reliability to the lowest. This system will allow you to identify the most effective control measures and manage the risks associated with storing and handling hazardous chemicals.

Assess and eliminate or control risks

Ensure:

  • you are familiar with the Managing Hazardous Chemicals in the Workplace - Code of Practice which provides guidance on how to manage the risks associated with hazardous chemicals
  • you follow the manufacturer/importer’s information provided in the SDS
    • hazards are identified – find out what could cause harm
    • risks are assessed. Understand the nature of the harm, the seriousness of the potential harm, and the likelihood of it happening
    • risks are eliminated so far as reasonably practicable
    • risks are controlled if it is not reasonably practicable to eliminate them. Implement the most effective control measures that are reasonably practicable in the circumstance in accordance with the hierarchy of control measures
    • control measures are reviewed over time to ensure they are working as expected and providing effective control
    • major hazard facilities have the appropriate licence.

Develop and implement safe systems of work

Ensure:

  • suitable storage facilities are maintained and procedures are available and followed
  • workers are trained and instructed in the proper handling and storage of chemicals, are aware of the risks, and know what to do in the event of a leak or exposure
  • workers are supervised when handling or storing hazardous chemicals
  • any instructions and controls outlined in safety data sheets, manufacturer specifications, and product labels are followed
  • an isolation and Lock Out Tag Out (LOTO) procedure is developed and followed when workers are required to perform tasks such as maintenance, repairs, installation, and cleaning of plant and equipment to prevent accidental start-up
  • appropriate chemical-resistant PPE is provided, workers are trained in its use and that it is worn correctly.

Correctly label, store and handle chemicals

Ensure:

  • you keep a register that lists all the hazardous chemicals used, stored and handled in your workplace. This register must include the current safety data sheet for each chemical listed and must be available to everyone who may be affected by the hazardous chemicals
  • HAZCHEM placards are displayed to assist emergency services if you store hazardous chemicals that exceed the ‘placard quantity’
  • warning signs are displayed near chemical storage areas
  • chemical storage containers and systems are maintained and monitored to ensure they continue to be fit for purpose
  • spill kits are available to manage any spills and leaks appropriately
  • fire extinguishers, suitable fire protection and firefighting equipment are available in areas where chemicals are used and stored
  • hazardous chemicals meet the packing and labelling requirements of the Australian Dangerous Goods Code when they are transported by road or rail
  • methods of access to bulk storage vessels are well maintained. For example, access stairways and ladders are maintained and are not allowed to fall into disrepair
  • monitoring systems and devices with warning systems are installed  and maintained to allow for chemical levels to be effectively monitored and controlled.

Plan for emergencies

Ensure:

  • an emergency plan and first aid plan are in place and staff are trained in them
  • you consult with your workers about the emergency plan and safety management system
  • workers’ health is monitored by a registered medical practitioner if they are likely to be exposed to hazardous chemicals
  • if a notifiable incident occurs, you must report it to SafeWork NSW immediately. It is an offence for a person who conducts a business or undertaking to not ensure that the regulator is notified immediately after becoming aware that a notifiable incident arising out of the conduct of the business or undertaking has occurred
  • if a spill or leak occurs, you must notify emergency services.

Related guidance material

Further information

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