hazardous materials cfr 1910.101-.126 safety & health consultation

Hazardous MaterialsCFR 1910.101-.126

Hazardous MaterialsCFR 1910.101-.126

Safety & Health Consultation

NUMBER OF SERIOUS VIOLATIONS – FY 2014

29CF

R 19

10 S

UBP

ARTS

107(g)(2)

107(b)(5)(iv)

106(e)(6)(ii)

107(b)(5)(i)

101(b)

48

58

63

66

131

HAZARDOUS MATERIALS [1910.101 – 126]

2

COMPRESSED GASES – HANDLING STORAGE AND USE

SPRAY BOOTH – AIR VELOCITY

CLASS I LIQUIDS – DISPENSING

SUBPART H

SPRAY AREAS – CLEANING WITH NON-SPARKING TOOLS

SPRAY BOOTH – FILTERS PROTECTED BY SPRINKLERS

Compressed GasesCompressed Gases

Safety & Health Consultation 1910.101(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-1-1965, which is incorporated by reference as specified in 1910.6

Compressed Gas CylindersCompressed Gas Cylinders

• 3.1.14, Never tamper with the safety relief devices in valves or cylinders

• 3.1.15, Never attempt to repair or to alter cylinders, valves, or safety relief devices

Safety & Health Consultation CGA Pamphlet P-1-1965

Compressed Gas CylindersCompressed Gas Cylinders

• 3.1.16, Never use cylinders as rollers, supports, or for any other purpose than to contain the contents as received


Big &

heavy

CGA Pamphlet P-1-1965

Compressed Gas CylindersCompressed Gas Cylinders• 3.1.17, Keep cylinder valve closed at all times,

except when cylinder is in active use• 3.1.18, 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


Compressed Gas CylindersCompressed Gas Cylinders• 3.1.19, 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


Moving CylindersMoving Cylinders


• 3.2.2, 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



• 3.2.4, Never handle a cylinder with a lifting magnet

• 3.2.5, Avoid dragging or sliding cylinders

Lifting magnet


• 3.2.6, Use suitable hand truck, fork truck, roll platform or similar device with cylinder firmly secured for transporting and unloading



!CGA Pamphlet P-1-1965

Storing CylindersStoring Cylinders


• 3.3.6, Do not store cylinders near highly flammable substances such as oil, gasoline or combustible waste


http://www.google.com/url?sa=i&rct=j&q=compressed+gas+storage&source=images&cd=&cad=rja&docid=1fsFLVVJW4_fEM&tbnid=zGGrnedW93N22M:&ved=0CAUQjRw&url=http://jrm.phys.ksu.edu/Safety/Training/&ei=TndAUc60Ouis0AGz24DACg&bvm=bv.43287494,d.dmg&psig=AFQjCNHHWsGmyWFwCjbBwIfgvognpZo4xA&ust=1363265727150874

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Storing CylindersStoring Cylinders


• 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 storednear exit


Withdrawing Cylinder ContentWithdrawing Cylinder Content• 3.4.2, If cylinder content is not identified by

marking, return cylinder to the supplier without using


I’m not labeled!

!


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Withdrawing Cylinder ContentWithdrawing 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 ConsultationCGA Pamphlet P-1-1965

• 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


Withdrawing Cylinder ContentWithdrawing Cylinder Content


• 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


Withdrawing Cylinder ContentWithdrawing Cylinder Content


Safe Work PracticesSafe Work Practices• 3.4.9

– 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


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Safe Work PracticesSafe Work Practices


• 3.4.9– 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 GasesFlammable Gases

• 3.5– Indoor cylinder storage– Well protected– Well insulated– Dry– Twenty (20) feet from

flammable or combustible materials


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Flammable GasesFlammable 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


Poison GasesPoison 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-1 2000)


AcetyleneAcetylene

• Cylinders: In-plant transfer, handling, storage, and utilization of acetylene in cylinders shall be in accordance with Compressed Gas Association Pamphlet G-1-1966

Safety & Health Consultation 1910.102

Case ReportCase 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. ”


Case ReportCase 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.


Dangerous SituationDangerous 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



Flammable and Combustible LiquidsCFR 1910.106

Flammable and Combustible LiquidsCFR 1910.106


IntroductionIntroduction

• 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

1910.106


DefinitionsDefinitions• 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 100oF, and are more

dangerous than combustible liquids, since they may be ignited at room temperature

• Combustible liquids have flash points at or above 100oF• Although combustible liquids have higher flash points than

flammable liquids, they can pose serious fire and/or explosion hazards when heated

1910.106(a)(14)

DefinitionsDefinitions


• 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.

1910.106(a)(14)


• 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 1910.106(a)(18)


• 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 1910.106(a)(18)(i)


• 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 1910.106(a)(18)(ii)


• 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 1910.106(a)(18)(ii)(a)


• 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 1910.106(a)(18)(ii)(b)


• 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 1910.106(a)(18)(iii)


• 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 1910.106(19)


• Class I liquids are divided into three classes:–Class 1A–Class 1B–Class 1C

Safety & Health Consultation 1910.106(19)


• 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 1910.106(19)(i)


• 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 1910.106(19)(ii)


• 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 1910.106(19)(iii)


Classes of Flammableand Combustible Liquids

Classes of Flammableand Combustible Liquids

IIIA

II

IC

IA IB

200

140

100

73

Fla

sh P

oin

t (o F

)

100

Boiling Point (oF)

Combustible(FP > 100oF)

Flammable(FP < 100oF)

1910.106(a)(18)

1910.106(a)(19)


Classes of Some Flammable LiquidsClasses of Some Flammable Liquids

CLASS IA

CLASS IB

CLASS IC

Common Name Flash Point (oF)

Ethyl Ether -49

Gasoline -45

Methyl Ethyl Ketone 21

Toluene 40

Xylene 81-115

Turpentine 95

Flammable (Explosive) LimitsFlammable (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.”


• 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.”



• 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.”




Program ComponentsProgram 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:


Sources of IgnitionSources 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:

1910.106(e)(6)(i)


Static ElectricityStatic 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


• Class I liquids shall not be dispensed into containers unless the nozzle and container are electrically interconnected

Safety & Health Consultation 1910.106(e)(6)(ii)


BondingBonding

• 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

1910.106(e)(6)(ii)


GroundingGrounding

• 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

1910.106(e)(6)(ii)


VentilationVentilation

Always provide adequate ventilation to reduce the potential for ignition of flammable vapors.

1910.106(a)(31)


Storage FundamentalsStorage 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


Storage of Flammable and Combustible Liquids

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

1910.106(d)(5)(i)

1910.106(d)(5)(iii)


Safety Cans for Storage and TransferSafety 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

1910.106(a)(29)


Flame Arrester ScreenFlame 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


Storage CabinetsStorage 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

1910.106(d)(3)(i)

1910.106(d)(3)(ii)

1910.106(d)(3)(ii)(a)


Fire ControlFire 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

1910.106(d)(7)(i)

1910.106(d)(7)(iii)

1910.106(d)(7)(iv)


Transferring Flammable Liquids

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:

1910.106(e)(2)(iv)(d)


Self-Closing Safety FaucetSelf-Closing Safety Faucet

• Bonding wire between

drum and container

• Grounding wire

between drum and

ground

• Safety vent in drum


Safety PumpSafety 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


Waste and ResidueWaste 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.

1910.106(e)(9)(iii)


Safe Handling FundamentalsSafe 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


Safe Handling FundamentalsSafe 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 Finishing1910.107

Spray Finishing1910.107


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Definitions 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



• 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.



• 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



• 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



• Dry spray booth–A spray booth not equipped with a water

washing system as described in subparagraph (4) of this paragraph.


Definitions 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 1910.107(a)(5)(i) – (v)

Separation of OperationsSeparation 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 1910.107(b)(8)


• 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 1910.107(c)(2) – (3)

Process Safety Management of Highly Hazardous Chemicals

CFR 1910.119

Process Safety Management of Highly Hazardous Chemicals

CFR 1910.119


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Why Did OSHA Develop PSM?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


• In 1991, OSHA and EPA respectively, Released the Standards, PSM & RMP that Applies to Those Companies that are Affected by The Standards.



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



Covered Facilities 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 Ammonia 10,000 lbs.• Chlorine 1,000 lbs.


• A process which involves a flammable liquid or gas (as defined in 1910.1200(c) of this part) on-site in one location, in a quantity of 10,000 pounds (4535.9 kg) or more


Covered Facilities Covered Facilities

Process Safety InformationProcess Safety Information


• Pertaining to the hazards of the highly hazardous chemicals: – Hazards of the process– Technology of the process; and, – The equipment in the process

1910.119(d)


Process Safety InformationProcess Safety Information

1910.119(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


SummarySummary

• 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


Your Questions?Your Questions?

hazardous materials cfr 1910.101-.126 safety & health consultation

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