Hazardous Materials
CFR 1910.101-.126
Safety & Health Consultation
HAZARDOUS MATERIALS [1910.101 – 126]
29CFR 1910 SUBPARTS
101(b)
131
SPRAY BOOTH – AIR VELOCITY
107(b)(5)(i)
66
CLASS I LIQUIDS – DISPENSING
106(e)(6)(ii)
SUBPART H
COMPRESSED GASES – HANDLING STORAGE AND USE
63
SPRAY BOOTH – FILTERS PROTECTED BY SPRINKLERS
107(b)(5)(iv)
58
SPRAY AREAS – CLEANING WITH NON-SPARKING TOOLS
107(g)(2)
48
2
NUMBER OF SERIOUS VIOLATIONS – FY 2014
Compressed Gases
• 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
Safety & Health Consultation
1910.101(b)
Compressed 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 Cylinders
• 3.1.16, 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-1-1965
Compressed 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
Safety & Health Consultation
CGA Pamphlet P-1-1965
Compressed 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
Safety & Health Consultation
CGA Pamphlet P-1-1965
Moving 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
Safety & Health Consultation
CGA Pamphlet P-1-1965
Moving Cylinders
Lifting magnet
• 3.2.4, Never handle a cylinder with a lifting
magnet
• 3.2.5, Avoid dragging or sliding cylinders
CGA Pamphlet P-1-1965
Safety & Health Consultation
Moving Cylinders
• 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
!
CGA Pamphlet P-1-1965
Storing Cylinders
• 3.3.6, Do not store
cylinders near
highly flammable
substances such as
oil, gasoline or
combustible waste
Safety & Health Consultation
CGA Pamphlet P-1-1965
Storing 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 stored
near exit
Safety & Health Consultation
CGA Pamphlet P-1-1965
Withdrawing Cylinder Content
• 3.4.2, If cylinder content is not identified by
marking, return cylinder to the supplier without
using
I’m not
labeled!
!
Safety & Health Consultation
CGA Pamphlet P-1-1965
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-1-1965
Withdrawing Cylinder Content
• 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
CGA Pamphlet P-1-1965
Withdrawing 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
Safety & Health Consultation
CGA Pamphlet P-1-1965
Safe 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
Safety & Health Consultation
CGA Pamphlet P-1-1965
Safe 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
Safety & Health Consultation
CGA Pamphlet P-1-1965
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-1-1965
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-1-1965
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-1 2000)
Safety & Health Consultation
CGA Pamphlet P-1-1965
Acetylene
• Cylinders: In-plant transfer,
handling, storage, and
utilization of acetylene in
cylinders shall be in
accordance with
Compressed Gas
Association Pamphlet G-11966
Safety & Health Consultation
1910.102
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
Safety & Health Consultation
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 1910.106
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
1910.106
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 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
Safety & Health Consultation
1910.106(a)(14)
Definitions
• 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.
Safety & Health Consultation
1910.106(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
1910.106(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
1910.106(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
1910.106(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
1910.106(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
1910.106(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
1910.106(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
1910.106(19)
Definitions
• Class I liquids are divided into three
classes:
– Class 1A
– Class 1B
– Class 1C
Safety & Health Consultation
1910.106(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
1910.106(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
1910.106(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
1910.106(19)(iii)
Flash Point (oF)
Classes of Flammable
and Combustible Liquids
200
IIIA
Combustible
(FP > 100oF)
140
II
100
IC
73
IA
Flammable
(FP < 100oF)
IB
100
Boiling Point (oF)
Safety & Health Consultation
1910.106(a)(18)
1910.106(a)(19)
Classes of Some Flammable Liquids
Common Name
Flash Point (oF)
CLASS IA
Ethyl Ether
-49
CLASS IB
Gasoline
-45
Methyl Ethyl Ketone
21
Toluene
40
Xylene
81-115
Turpentine
95
CLASS IC
Safety & Health Consultation
Flammable (Explosive) Limits
• Flammable Range
– The range of a combustible vapor or gasair mixture between the upper and lower
flammable limits.
– Also, known as the “explosive range.”
Safety & Health Consultation
Flammable (Explosive) Limits
• 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
Program Components
A good plan for safe use of flammable and
combustible liquids contains at least these
components:
•
•
•
•
Control of ignition sources
Proper storage
Fire control
Safe handling
Safety & Health Consultation
Sources of Ignition
Must take adequate precautions to prevent ignition of
flammable vapors. Some sources of ignition include:
•
•
•
•
•
•
•
Open flames
Smoking
Static electricity
Cutting and welding
Hot surfaces
Electrical and mechanical sparks
Lightning
Safety & Health Consultation
1910.106(e)(6)(i)
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
Safety & Health Consultation
Sources of Ignition
• 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)
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
Safety & Health Consultation
1910.106(e)(6)(ii)
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
Safety & Health Consultation
1910.106(e)(6)(ii)
Ventilation
Always provide adequate ventilation
to reduce the potential for ignition of
flammable vapors.
Safety & Health Consultation
1910.106(a)(31)
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:
Inside storage room
• closed metal containers inside a
storage cabinet, or
• safety cans, or
1910.106(d)(5)(i)
• an inside storage room
Safety & Health Consultation
1910.106(d)(5)(iii)
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
Safety & Health Consultation
1910.106(a)(29)
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
Safety & Health Consultation
1910.106(d)(3)(i)
1910.106(d)(3)(ii)
1910.106(d)(3)(ii)(a)
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
Safety & Health Consultation
1910.106(d)(7)(i)
1910.106(d)(7)(iii)
1910.106(d)(7)(iv)
Transferring Flammable
Liquids
Since there is a sizeable risk whenever
flammable liquids are handled, OSHA allows
only four methods for transferring these
materials:
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
Safety & Health Consultation
1910.106(e)(2)(iv)(d)
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
Combustible waste and residue must be kept to a minimum,
stored in covered metal receptacles and disposed of daily.
Waste drum with
disposal funnel
Safety & Health Consultation
Safety disposal can
1910.106(e)(9)(iii)
Oily-waste can
(self-closing lid)
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.
Safety & Health Consultation
Spray Finishing
1910.107
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
1910.107(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
1910.107(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
1910.107(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
1910.107(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
1910.107(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
1910.107(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
1910.107(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
1910.107(c)(2) – (3)
Process Safety Management of Highly
Hazardous Chemicals
CFR 1910.119
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
Why Did OSHA Develop PSM?
• 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
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
• Anhydrous Ammonia
• Chlorine
Safety & Health Consultation
Threshold Quantity (TQ)
10,000 lbs.
1,000 lbs.
1910.119(a)(1)
Covered Facilities
• 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
Safety & Health Consultation
1910.119(a)(1)
Process 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
Safety & Health Consultation
1910.119(d)
Process Safety Information
• 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
1910.119(d)
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?
Safety & Health Consultation