Hazardous Materials CFR Safety & Health Consultation

N UMBER OF S ERIOUS V IOLATIONS – FY CFR 1910 S UBPARTS H AZARDOUS M ATERIALS [ – 126] 2 C OMPRESSED G ASES – H ANDLING S TORAGE AND U SE S PRAY B OOTH – A IR V ELOCITY C LASS I L IQUIDS – D ISPENSING SUBPART H S PRAY A REAS – C LEANING WITH N ON - SPARKING T OOLS S PRAY B OOTH – F ILTERS P ROTECTED BY S PRINKLERS

Compressed Gases Safety & Health Consultation (b) The in-plant handling, storage, and utilization of all compressed gases in cylinders, portable tanks, rail tank cars, or motor vehicle cargo tanks shall be in accordance with Compressed Gas Association (CGA) Pamphlet P , which is incorporated by reference as specified in

Compressed Gas Cylinders , Never tamper with the safety relief devices in valves or cylinders , Never attempt to repair or to alter cylinders, valves, or safety relief devices Safety & Health Consultation CGA Pamphlet P

Compressed Gas Cylinders , Never use cylinders as rollers, supports, or for any other purpose than to contain the contents as received Safety & Health Consultation Big & heav y CGA Pamphlet P

Compressed Gas Cylinders , Keep cylinder valve closed at all times, except when cylinder is in active use , Notify cylinder owner if any condition might have permitted any foreign substance to enter the cylinder or valve: –Provide details of incident –Provide the cylinder serial number Safety & Health Consultation CGA Pamphlet P

Compressed Gas Cylinders , Do not place cylinders where they might become part of an electric circuit When cylinders are used in conjunction with electric welding, precautions must be taken against accidentally grounding cylinders and allowing them to be burned by electric welding arc Safety & Health Consultation CGA Pamphlet P

Moving Cylinders Safety & Health Consultation CGA Pamphlet P , Do not lift cylinders by the cap 3.2.3, Never drop cylinders nor permit them to strike against each other or against other surfaces violently

Moving Cylinders Safety & Health Consultation 3.2.4, Never handle a cylinder with a lifting magnet 3.2.5, Avoid dragging or sliding cylinders Lifting magnet CGA Pamphlet P

3.2.6, Use suitable hand truck, fork truck, roll platform or similar device with cylinder firmly secured for transporting and unloading Safety & Health Consultation Moving Cylinders ! CGA Pamphlet P

Storing Cylinders Safety & Health Consultation 3.3.6, Do not store cylinders near highly flammable substances such as oil, gasoline or combustible waste CGA Pamphlet P

Storing Cylinders Safety & Health Consultation 3.3.8, Do not store cylinders near elevators or gangways, or in locations where heavy moving objects may strike or fall on them LP gas stored near exit CGA Pamphlet P

Withdrawing Cylinder Content 3.4.2, If cylinder content is not identified by marking, return cylinder to the supplier without using Safety & Health Consultation I’m not labeled! ! CGA Pamphlet P

Withdrawing Cylinder Content 3.4.4, Before using a cylinder, be sure it is properly supported to prevent it from being knocked over 3.4.5, Suitable pressure regulating devices must be used Safety & Health Consultation CGA Pamphlet P

3.4.6, Never force connections 3.4.7, Where compressed gas cylinders are connected to a manifold, all related equipment, such as regulators, must be of proper design Safety & Health Consultation Withdrawing Cylinder Content CGA Pamphlet P

3.4.8, Do not mix regulators, gages, hoses and other appliances provided for use with a particular gas or group of gases with incompatible materials/gases Safety & Health Consultation Withdrawing Cylinder Content CGA Pamphlet P

Safe Work Practices –Open cylinder slowly –Point valve opening away from yourself & others –Never use wrenches or tools except those provided by the supplier or approved by the gas manufacturer –Avoid the use of a wrench on a valve equipped with a handwheel Safety & Health Consultation CGA Pamphlet P

Safe Work Practices Safety & Health Consultation CGA Pamphlet P –Never hammer on the valve wheel –Frozen, corroded valves; contact the supplier –Use check valves if cylinder is apt to be contaminated by feedback of materials –Before removing a regulator, close the cylinder valve and release all the pressure from the regulator

Flammable Gases 3.5 –Indoor cylinder storage –Well protected –Well insulated –Dry –Twenty (20) feet from flammable or combustible materials Safety & Health Consultation CGA Pamphlet P

Flammable Gases 3.5.1, Do not store cylinders near highly flammable solvents, combustible waste material and similar substances, or near unprotected electrical connections, gas flames or other sources of ignition 3.5.2, Never use a flame to detect flammable gas leaks; use soapy water Safety & Health Consultation CGA Pamphlet P

Poison Gases 3.6.1, Personnel handling and using poison gases should have available for immediate use gas masks or self-contained breathing apparatus approved by U.S. Bureau of Mines* for the particular service desired *NOTE: This approval for respirators has been up-dated to the requirements of NIOSH (CGA P ) Safety & Health Consultation CGA Pamphlet P

Acetylene Cylinders: In-plant transfer, handling, storage, and utilization of acetylene in cylinders shall be in accordance with Compressed Gas Association Pamphlet G Safety & Health Consultation

Case Report “A fitter with a work van left an E size Oxygen and Acetylene cylinder on the back seat of a Toyota dual cab over the weekend. The Acetylene cylinder must not have fully closed and a small leak occurred. Over the weekend the Acetylene had accumulated in the van. ” Safety & Health Consultation

Case Report “On the Monday morning the fitter approached the van and opened the door, a large explosion took place. We believe the ignition could have been caused by either the internal light, the automatic door control or by a mobile phone which was on the front seat of the van. The fellow was also a smoker. He has damage to his ear drums and facial damage. As you can see by the attached photos he was very lucky. Safety & Health Consultation

Dangerous Situation Flammability limits: Lower: 2.5% Upper: 100% – an extremely wide range! Use or store only in a well-ventilated area. (Inside of the truck is not well ventilated.) NFPA RATINGS: Health 1; Flammability 4; Reactivity 3 Safety & Health Consultation

Flammable and Combustible Liquids CFR

Safety & Health Consultation Introduction The two primary hazards associated with flammable and combustible liquids are explosion and fire Safe handling and storage of flammable liquids requires the use of approved equipment and practices per OSHA standards

Safety & Health Consultation Definitions Flash point means the minimum temperature at which a liquid gives off enough vapor to form an ignitable mixture In general, the lower the flash point, the greater the hazard Flammable liquids have flash points below 100 o F, and are more dangerous than combustible liquids, since they may be ignited at room temperature Combustible liquids have flash points at or above 100 o F Although combustible liquids have higher flash points than flammable liquids, they can pose serious fire and/or explosion hazards when heated (a)(14)

Definitions Safety & Health Consultation Flash Point –Flash point means the minimum temperature at which a liquid gives off vapor within a test vessel in sufficient concentration to form an ignitable mixture with air near the surface of the liquid. The flash point is normally an indication of susceptibility to ignition (a)(14)

Definitions Combustible Liquid –Combustible liquid means any liquid having a flash point at above 100°F (37.8 °C). –Combustible liquids are divided into two classes: Class II Class III Safety & Health Consultation (a)(18)

Definitions Class II Liquids –Class II liquids shall include those with a flash point at or above 100°F (37.8°C) and below 140°F (60°C) Safety & Health Consultation (a)(18)(i)

Definitions Class III Liquids –Class III liquids shall include those with flash points at or above 140°F (60°C). –Class III are divided into two classes: Class IIIA Class IIIB Safety & Health Consultation (a)(18)(ii)

Definitions Class IIIA Liquids –Class III liquids shall include those with flash points at or above 140°F (60°C) and below 200°F (93.3°C) Safety & Health Consultation (a)(18)(ii)(a)

Definitions Class IIIB Liquids –Class IIIB liquids shall include those with a flash point at or above 200°F (93.3°C). –This section does not regulate Class IIIB liquids. Safety & Health Consultation (a)(18)(ii)(b)

Definitions Note: When a combustible liquid is heated to within 30°F (16.7°C) of its flash point, it shall be handled in accordance with the requirements for the next lower class of liquids Safety & Health Consultation (a)(18)(iii)

Definitions Flammable Liquid –Flammable liquid means any liquid having a flash point below 100 °F (37.8 °C) –Flammable liquids shall be known as Class I liquids Safety & Health Consultation (19)

Definitions Class I liquids are divided into three classes : –Class 1A –Class 1B –Class 1C Safety & Health Consultation (19)

Definitions Class 1A –Class 1A shall include liquids having flash points below 73 °F (22.8°C) and having a boiling point below 100 °F (37.8°C) –Examples: Ethyl Ether, Isopropyl Chloride, Pentane Safety & Health Consultation (19)(i)

Definitions Class 1B Liquids –Class 1B shall include liquids having flash points below 73°F (22.8°C) and having a boiling point at or above 100°F (37.8°C) –Example: Acetone, Gasoline, Toluene Safety & Health Consultation (19)(ii)

Definitions Class 1C –Class 1C shall include liquids having flash points at or above 73°F (22.8°C) and below 100°F (37.8°C) –Examples: Amyl Alcohol, Naphtha, Xylene Safety & Health Consultation (19)(iii)

Safety & Health Consultation Classes of Flammable and Combustible Liquids IIIA II IC IAIB Flash Point ( o F) 100 Boiling Point ( o F) Combustible (FP > 100 o F) Flammable (FP < 100 o F) (a)(18) (a)(19)

Safety & Health Consultation Classes of Some Flammable Liquids CLASS IA CLASS IB CLASS IC Common NameFlash Point ( o F) Ethyl Ether-49 Gasoline-45 Methyl Ethyl Ketone21 Toluene40 Xylene Turpentine95

Flammable (Explosive) Limits Flammable Range –The range of a combustible vapor or gas- air mixture between the upper and lower flammable limits. – Also, known as the “explosive range.” Safety & Health Consultation

Lower Flammable Limit –The lowest concentration at which a combustible gas forms a flammable mixture. –Below the LFL there is too little combustible fuel to sustain a flame. –Also, known as “Lower Explosive Limit or LEL.” Safety & Health Consultation Flammable (Explosive) Limits

Upper Flammable Limit –The highest concentration at which a combustible gas forms a flammable mixture. –Above the UFL there is too little oxygen to sustain a flame. Better known as “too rich” to burn. –Also, known as “Upper Explosive Limit or UEL.” Safety & Health Consultation Flammable (Explosive) Limits

Safety & Health Consultation Program Components Control of ignition sources Proper storage Fire control Safe handling A good plan for safe use of flammable and combustible liquids contains at least these components:

Safety & Health Consultation Sources of Ignition Open flames Smoking Static electricity Cutting and welding Hot surfaces Electrical and mechanical sparks Lightning Must take adequate precautions to prevent ignition of flammable vapors. Some sources of ignition include: (e)(6)(i)

Safety & Health Consultation Static Electricity Generated when a fluid flows through a pipe or from an opening into a tank Main hazards are fire and explosion from sparks containing enough energy to ignite flammable vapors Bonding or grounding of flammable liquid containers is necessary to prevent static electricity from causing a spark

Sources of Ignition Class I liquids shall not be dispensed into containers unless the nozzle and container are electrically interconnected Safety & Health Consultation (e)(6)(ii)

Safety & Health Consultation Bonding Physically connect two conductive objects together with a bond wire to eliminate a difference in static charge potential between them Must provide a bond wire between containers during flammable liquid filling operations, unless a metallic path between them is otherwise present (e)(6)(ii)

Safety & Health Consultation Grounding Eliminates a difference in static charge potential between conductive objects and ground Although bonding will eliminate a difference in potential between objects, it will not eliminate a difference in potential between these objects and earth unless one of the objects is connected to earth with a ground wire (e)(6)(ii)

Safety & Health Consultation Ventilation Always provide adequate ventilation to reduce the potential for ignition of flammable vapors (a)(31)

Safety & Health Consultation Storage Fundamentals Identify incompatible chemicals – check the Safety Data Sheet Isolate and separate incompatible materials –Isolate by storing in another area or room –Degree of isolation depends on quantities, chemical properties and packaging –Separate by storing in same area or room, but apart from each other

Safety & Health Consultation Storage of Flammable and Combustible Liquids Storage must not limit the use of exits, stairways, or areas normally used for the safe egress of people In office occupancies: –Storage prohibited except that which is required for maintenance and operation of equipment –Storage must be in: closed metal containers inside a storage cabinet, or safety cans, or an inside storage room Inside storage room (d)(5)(i) (d)(5)(iii)

Safety & Health Consultation Safety Cans for Storage and Transfer Approved container of not more than 5 gallons capacity Spring-closing lid and spout cover Safely relieves internal pressure when exposed to fire (a)(29)

Safety & Health Consultation Flame Arrester Screen Prevents fire flashback into can contents Double wire-mesh construction Large surface area provides rapid dissipation of heat from fire so that vapor temperature inside can remains below ignition point

Safety & Health Consultation Storage Cabinets Not more than 60 gal of Class I and/or Class II liquids, or not more than 120 gal of Class III liquids permitted in a cabinet Must be conspicuously labeled, “Flammable - Keep Fire Away” Doors on metal cabinets must have a three-point lock (top, side, and bottom), and the door sill must be raised at least 2 inches above the bottom of the cabinet (d)(3)(i) (d)(3)(ii) (d)(3)(ii)(a)

Safety & Health Consultation Fire Control Suitable fire control devices, such as small hose or portable fire extinguishers must be available where flammable or combustible liquids are stored Open flames and smoking must not be permitted in these storage areas Materials which react with water must not be stored in the same room with flammable or combustible liquids (d)(7)(i) (d)(7)(iii) (d)(7)(iv)

Safety & Health Consultation Transferring Flammable Liquids 1.Through a closed piping system 2.From safety cans 3.By gravity through an approved self-closing safety faucet 4.By means of a safety pump Since there is a sizeable risk whenever flammable liquids are handled, OSHA allows only four methods for transferring these materials: (e)(2)(iv)(d)

Safety & Health Consultation Self-Closing Safety Faucet Bonding wire between drum and container Grounding wire between drum and ground Safety vent in drum

Safety & Health Consultation Safety Pump Faster and safer than using a faucet Spills less likely No separate safety vents in drum required Installed directly in drum bung opening Some pump hoses have integral bonding wires

Safety & Health Consultation Waste and Residue Waste drum with disposal funnel Safety disposal can Oily-waste can (self-closing lid) Combustible waste and residue must be kept to a minimum, stored in covered metal receptacles and disposed of daily (e)(9)(iii)

Safety & Health Consultation Safe Handling Fundamentals Carefully read the manufacturer’s label on the flammable liquid container before storing or using it Practice good housekeeping in flammable liquid storage areas Clean up spills immediately, then place the cleanup rags in a covered metal container Only use approved metal safety containers or original manufacturer’s container to store flammable liquids

Safety & Health Consultation Safe Handling Fundamentals Keep the containers closed when not in use and store away from exits or passageways Use flammable liquids only where there is plenty of ventilation Keep flammable liquids away from ignition sources such as open flames, sparks, smoking, cutting, welding, etc.

Spray Finishing Safety & Health Consultation

Definitions Aerated Solid Powders –Aerated powders shall mean any powdered material used as a coating material which shall be fluidized within a container by passing air uniformly from below. It is common practice to fluidize such materials to form a fluidized powder bed and then dip the part to be coated into the bed in a manner similar to that used in liquid dipping. Such beds are also used as sources for powder spray operation Safety & Health Consultation (a)(1)

Definitions Spraying Area –Any area in which dangerous quantities of flammable vapors or mists, or combustible residues, dusts, or deposits are present due to the operation of spraying processes. Safety & Health Consultation (a)(2)

Definitions Spray Booth –A power-ventilated structure provided to enclose or accommodate a spraying operation to confine and limit the escape of spray, vapor, and residue, and to safely conduct or direct them to an exhaust system Safety & Health Consultation (a)(3)

Definitions Waterwash spray booth – A spray booth equipped with a water washing system designed to minimize dusts or residues entering exhaust ducts and to permit the recovery of overspray finishing material Safety & Health Consultation (a)(4)

Definitions Dry spray booth –A spray booth not equipped with a water washing system as described in subparagraph (4) of this paragraph. Safety & Health Consultation (a)(5)

Definitions Dry spray booth –A dry spray booth may be equipped with distribution or baffle plates to promote an even flow of air through the booth or cause the deposit of overspray before it enters the exhaust duct; or overspray dry filters to minimize dusts or residues entering exhaust ducts; or where dry powders are being sprayed, with powder collection systems so arranged in the exhaust to capture oversprayed material. Safety & Health Consultation (a)(5)(i) – (v)

Separation of Operations Each spray booth shall be separated from other operations by: – not less than 3 feet, or – by a greater distance, or – by a partition or wall to reduce danger Safety & Health Consultation (b)(8)

Sources of Ignition There will be no open flame or spark producing equipment in any spray area nor within 20 feet Space heating appliances, steam pipes, or hot surfaces shall not be located in the spray area Safety & Health Consultation (c)(2) – (3)

Process Safety Management of Highly Hazardous Chemicals CFR Safety & Health Consultation

Why Did OSHA Develop PSM? Bhopal, India (1984) –2,000 deaths Isocyanate release Pasadena, TX (1989) –23 deaths, 132 injuries Petroleum explosion Cincinnati, OH (1990) –2 deaths Explosion Sterlington, LA (1991) –8 deaths, 128 injuries Chemical release Safety & Health Consultation

In 1991, OSHA and EPA respectively, Released the Standards, PSM & RMP that Applies to Those Companies that are Affected by The Standards. Safety & Health Consultation Why Did OSHA Develop PSM?

Process Safety Management is a regulation, promulgated by OSHA, intended to prevent an incident like the 1984 Bhopal Disaster And…to Prevent Release of: –Toxic, –Reactive, –Flammable, or –Explosive chemicals Safety & Health Consultation Why Did OSHA Develop PSM?

Covered Facilities Those Who Use Chemicals in Appendix A: A List of highly hazardous chemicals, toxics and reactive (Mandatory). Contains a listing of toxic and reactive highly hazardous chemicals which present a potential for a catastrophic event at or above the threshold quantity Examples –Chemical Threshold Quantity (TQ) Anhydrous Ammonia10,000 lbs. Chlorine 1,000 lbs. Safety & Health Consultation (a)(1)

A process which involves a flammable liquid or gas (as defined in (c) of this part) on-site in one location, in a quantity of 10,000 pounds ( kg) or more Safety & Health Consultation (a)(1) Covered Facilities

Process Safety Information Safety & Health Consultation Pertaining to the hazards of the highly hazardous chemicals: –Hazards of the process –Technology of the process; and, –The equipment in the process (d)

Safety & Health Consultation Process Safety Information (d) Toxicity information*; –Permissible exposure limits; –Physical data; –Reactivity data: –Corrosivity data; –Thermal and chemical stability data; and –Hazardous effects of inadvertent mixing of different materials that could foreseeably occur *Note: Material Safety Data Sheets may be used to comply with this requirement to the extent they contain the information required

Safety & Health Consultation Summary The two primary hazards associated with flammable and combustible liquids are explosion and fire Safe handling and storage of flammable liquids requires the use of approved equipment and practices per OSHA standards An excellent reference on this topic is National Fire Protection Association Standard No. 30, Flammable and Combustible Liquids Code

Safety & Health Consultation Your Questions?