Flammable and Combustible Liquids

Transcription

1 Page #: 1 of 11 Last Reviewed/Update Date: 5/20/13 Flammable and Combustible Liquids 1. Purpose / Background This document has been developed to help ensure that flammable and combustible liquids are used and stored safely. Fires involving flammable liquid vapors occur readily are very difficult to extinguish. Massachusetts Building Codes and Fire Codes, MIT insurance carriers, City of Cambridge ordinances, and OSHA Standards require the safe storage and use of flammable and combustible liquids. 2. Scope This SOP outlines the requirements and guidelines for the safe storage, dispensing and use of flammable and combustible liquids in MIT laboratories and operations. It also describes the permitting and licensing process for the use and storage of these materials, as required by the City of Cambridge and the Massachusetts Department of Fire Services. 3. Prerequisites All Departments, Laboratories or Centers (DLC) must posses a current flammable storage permit and/or license from the Cambridge Fire Department before storing flammable or combustible liquids. Laboratories where workers, researchers and students use and storage flammable and combustible liquids shall complete a written Chemical Hygiene Plan (a template is available through the EHS Office.) Non-laboratory areas must comply with the requirements of the MIT Hazard Communication Program. This includes completing a written Hazard Communication Program. 4. Procedures 4.1 Maximum Allowable Quantity of Flammable and Combustible Liquids The Massachusetts Building Code 780 CMR Table (1) and Table specify the maximum quantities of flammable and combustible liquids to be stored. As outlined in the summary table below, the allowable amounts of flammable liquids is driven by floor level and the fire-resistance ratings. For clarity, please note that Class IB is bolded in the table below. This class of material is the most common stored and used in MIT wet laboratories.

2 Page #: 2 of 11 Last Reviewed/Update Date: 5/20/13 Floor level >9 Maximum allowable control areas per floor 4 (1 hour fire 3 (1 hour fire 2 (1 hour fire 2 (2 hour fire 2 (2 hour fire 1 (2 hour fire Summary of 780 CMR Table (1) and Table Maximum quantities of flammables allowed PER CONTROL AREA in a building with a SPRINKLER SYSTEM Maximum amount if all Maximum amount if all flammable/combustible liquids flammable/combustible liquids are outside approved cabinets are inside approved cabinets All Class IA: 60 gal (227 L) All Class IB: 240 gal (909 L) All Class IC: 240 gal (909L) IA,B,C combined: 240 gal (909 L) All Class II: 240 gal (909 L) All Class IA: 45 gal (170 L) All Class IB: 180 gal (682 L) All Class IC: 180 gal (682 L) IA,B,C combined: 180 gal (682 L) All Class II: 180 gal (682 L) All Class IA: 30 gal (113 L) All Class IB: 120 gal (454 L) All Class IC: 120 gal (454 L) IA,B,C combined: 120 gal (454 L) All Class II: 120 gal (454 L) All Class IA: 7.5 gal (28 L) All Class IB: 30 gal (114 L) All Class IC: 30 gal (114 L) IA,B,C combined: 30 gal (114 L) All Class II: 30 gal (114 L) All Class IA: 3 gal (11 L) All Class IB: 12 gal (45 L) All Class IC: 12 gal (45 L) IA,B,C combined: 12 gal (45 L) All Class II: 12 gal (45 L) All Class IA: 3 gal (11 L) All Class IB: 12 gal (45 L) All Class IC: 12 gal (45 L) IA,B,C combined: 12 gal (45 L) All Class II: 12 gal (45 L) All Class IA: 120 gal (454 L) All Class IB: 480 gal (1818 L) All Class IC: 480 gal (1818 L) IA,B,C combined: 480 gal All Class II: 480 gal All Class IA: 90 gal (341 L) All Class IB: 360 gal (1364 L) All Class IC: 360 gal (1364 L) IA,B,C combined: 360 gal All Class II: 360 gal ( L) All Class IA: 60 gal (227 L) All Class IB: 240 gal (909 L) All Class IC: 240 gal (909 L) IA,B,C combined: 240 gal (909 L) All Class II: 240 gal (909 L) All Class IA: 15 gal (57 L) All Class IB: 60 gal (228 L) All Class IC: 60 gal (228 L) IA,B,C combined: 60 gal (228 L) All Class II: 60 gal (228 L) All Class IA: 6 gal (22 L) All Class IB: 24 gal (90 L) All Class IC: 24 gal (90 L) IA,B,C combined: 24 gal (90 L) All Class II: 24 gal (90 L) All Class IA: 6 gal (22 L) All Class IB: 24 gal (90 L) All Class IC: 24 gal (90 L) IA,B,C combined: 24 gal (90 L) All Class II: 24 gal (90 L) 4.2 Control Area Fire Resistance Rating Floor construction of all control areas must have a minimum two-hour fire-resistance rating regardless of the floor level. Walls and doors in control areas on floor levels 1 through 3 may have a one-hour fireresistance rating. Most walls and doors in MIT laboratories have a fire resistance rating of 1-hour. Therefore, laboratories located on floors 1-3 can be considered a separate control area.

3 Page #: 3 of 11 Last Reviewed/Update Date: 5/20/13 Walls, doors, and floors in control areas on floor 4 and above must have a minimum two-hour fire-resistance rating. Most laboratories at MIT located on floor 4 and above could not be considered a separate control area. Therefore, one must assume that the entire floor would be one control area on floor levels 4 and above. This limits the amount of flammable liquids that can be stored in laboratories on floor levels 4 and above. See Appendix A for an example. 4.3 Container Size The maximum allowable container size is summarized in the following table. Flammable Combustible Container Type IA IB IC II III Glass 1 pint 1 quart 1 gal 1 gal 5 gal Approved Plastic 1 gal 5 gal 5 gal 5 gal 5 gal DOT Polyethylene 1 gal 5 gal 5 gal 60 gal 60 gal Safety Cans 2 gal 5 gal 5 gal 5 gal 5 gal DOT Drums 60 gal 60 gal 60 gal 60 gal 60 gal (Laboratory quantities) 4L (1.1gal) 20L(5gal) 20L(5gal) (same) (same) Approved 1 Portable Tank 660 gal 660 gal 660 gal 660 gal 660 gal Exception 1: Glass containers as large as 4L (1.1 gal.) shall be permitted to be used if needed and if the required purity would be adversely affected by storage in a metal or an approved plastic container, or if the liquid would cause excessive corrosion or degradation of a metal or an approved plastic container. Exception 2: Containers of not more that 227L (60 gal.) capacity shall be permitted in a separate area inside the building if the inside area meets the requirements of NFPA 30, Flammable and Combustible Liquids Code. 4.4 Storage Cabinets According to NFPA 30, not more than three approved storage cabinets may be located in a fire area. A fire area has floors, doors, and walls with a fire-resistance rating of at least 1 hour. Note that this definition differs from the control area definition given above. Cabinets for flammable liquids must be Factory Mutual (FM) or Underwriters Laboratories (UL) listed to be considered approved cabinets. Not more than 60 gallons (454 L) of flammable and combustible liquids (Class I and II) can be stored in each flammable storage cabinet. Not more than a total of 120 gallons of Class I, II, and IIIA shall be stored in each cabinet. 4.5 Engineering Controls for Storage and Dispensing Areas

4 Page #: 4 of 11 Last Reviewed/Update Date: 5/20/13 Room/Area Design and Construction: Electrical classification shall conform to the NEC classification requirements. Generally, Class I, Division I for areas used for dispensing and Class I, Division II for storage only areas. This is intended to apply to area used exclusively for dispensing (eg red label rooms ) as opposed to fume hoods or other lab areas where incidental dispensing may occur. Exhaust Ventilation: All inside storage rooms shall be equipped with a continuous mechanical exhaust ventilation system. Exhausted air shall be directed, as far as practical, directly to the exterior of the building and if ducts are used, they are not to be used for other purposes. Generally one cfm of exhaust per square foot of storage area is required. Local ventilation at open transfer points may also be required. A face velocity of 100 feet per minute is generally sufficient. It is not recommended to exhaust storage cabinets that are used exclusively for non-toxic flammable liquids as this may have the potential to compromise the fire rating. However, consideration should be given to the storage of highly toxic materials/odiferous flammable liquids. It is good practice to store these in an exhausted flammable storage cabinet. Storage Cabinets: Shall meet NFPA 30 Flammable and Combustible Liquids Code and must be Factory Mutual approved. New cabinets used for storage shall have approx. 2 inch deep leak proof pans at the base to contain spills. Cabinets shall be labeled Flammable-Keep Fire Away, Refrigerators: All refrigerators designated to store flammable liquids must comply with NFPA 45 and be UL listed for the appropriate electrical classification such as Class 1, Group C and D. Cold Rooms: Flammable and combustible liquids cannot be stored or used in cold rooms unless the electrical and refrigeration equipment is specifically designed as explosion proof and mechanically ventilated with an exhaust rate of 6 air changes per hour. Grounding System: For dispensing of flammable and combustible liquids of more than one gallon from metal containers, grounding bars, cables and clamps shall be provided. See section 4.7 for information on grounding and bonding. Spill Control and Containment: The storage area shall have containment sills as well as spill control equipment readily available. Metal Containers: Only approved metal containers shall be used for flammable and combustible liquids stored in containers greater than 5 gallons. 4.6 Administrative and Procedural Controls for Storage and Dispensing Areas. Training: Anyone using flammable and combustible liquids must have adequate training and knowledge of their hazards and of the practices and procedures for working with them safely. See section 6 for detailed training requirements. Hot Work Permit: A no open flame policy while using flammable or combustible liquids must be implemented. An MIT Hot Work Permit must be obtained prior to any welding or other Hot Work in areas where flammable and combustible materials are used. Flammable storage cabinets shall not be staged in hallways, stairwells or in the path of egress from a room or laboratory.

5 Page #: 5 of 11 Last Reviewed/Update Date: 5/20/13 Dispensing of Class I Liquids: Shall not be conducted in the paths of egress. Dispensing from containers that are less than 5 gallons, shall be done in a fume hood, well ventilated area, or an area specifically designed for dispensing (NFPA 30.) Dispensing from containers that are greater than 5 gallons, shall be done in a separate area outside the building or storage area designated for dispensing (NFPA 30.) 4.7 Grounding and Bonding Containers Grounding is accomplished when containers are connected to an earthing electrode or to a building grounding system. This prevents sparking between conductive containers and grounded structures. A bonding system connects different containers to keep them at the same electrical potential. This prevents the generation of static charge/sparks when dispensing/pouring flammable liquids. (See illustration). For bonding and grounding to be effective, a metal to metal connection must be maintained between the cables and the containers. Bonding and grounding cables

6 Page #: 6 of 11 Last Reviewed/Update Date: 5/20/13 must be durable and of low resistance. Clamps should make contact with metal through paint, rust and surface contamination. These connections can be of (2) types: 1. Permanent connections can be made using solid or braided wires and should incorporate either screw type clamps or other similar means. 2. Temporary connections should use only braided wires in conjunction with spring clamps or other similar methods of maintaining metal to metal contact. Single point clamps are superior to alligator type clamps for making direct contact. Bonding and grounding of non-conductive containers is not always practical. In lieu of this, special dispensing procedures should be developed that take into account the electrical characteristics of the Class 1 liquid involved. For this reason, it is recommended that only conductive containers be used to store and dispense Class 1 liquids. 4.8 Cambridge Fire Department Permits Use and storage permits shall be obtained from the Cambridge Fire Department for the storage of flammable liquids, gases and solids. If the amounts of flammable and combustible liquids stored are equal to or greater than those listed below, a license must also be obtained from the Cambridge License Commission. Contact the EHS Office for information regarding permits and licenses. Class I flammable liquids 793gallons Class II combustible liquids 10,000 gallons Class IIIA combustible liquids 10,000 gallons Class IIIB combustible liquids 10,000 gallons Flammable Gases (inside) 3,000 ft 3 Flammable Gases (outside) 10,000 ft 3 Flammable Solids 100 pounds 4.9 Applying for Permits Construction and Renovation projects Newly constructed laboratory spaces where the research or teaching work involves the storage of flammable liquid and gases will require a use and storage permit from the Cambridge Fire Department, Fire Prevention Office. The first step in the permit application process involves developing a chemical inventory. Once complete, the Department shall submit the inventory to the MIT Project Manager and the EHS Office for review. The EHS Office will work with the Project Team to apply for use and storage permit (and/or license,) as required. If the construction and renovation project involves the installation of a fuel oil storage tank, the quantity of oil storage (including day tanks and piping) must be included on the permit application.

7 Page #: 7 of 11 Last Reviewed/Update Date: 5/20/13 Refer to the MIT Permit and License SOP for additional guidance Increasing Flammable Liquid and Gas storage amounts Changes in research often results to increasing the quantity of flammable liquids and gasses stored in an existing space and must be evaluated for compliance with applicable codes (see Section 4.1) If an increase in the amount of flammable materials stored in an existing space or laboratory is planned, the DLC should contact the EHS Office for assistance. The EHS Office will work with the DLC and submit a revised application for flammable storage permit to CFD. 5. Roles & Responsibilities 5.1 The EHS Office is responsible for: Providing General Chemical Hygiene Training (web-based or classroom) and MIT Overview HAZCOM training that includes information on chemical hazards Maintaining up to date guidance pertaining to flammable liquids. Addressing questions or concerns pertaining to flammable liquids. Assisting with inspections of use and storage areas for flammable liquids. Provide expertise and assistance in obtaining flammable liquid and gas storage permits and licenses from the Cambridge Fire Department. Apply for and renew the flammable and combustible liquid and gas storage licenses and permits annually. 5.2 PI s/supervisors are responsible for: Ensuring that those individuals that they supervise who work with flammable liquids receive adequate training (see Section 6.0 for training requirements.) Ensuring that flammable liquids are used and stored safely in the laboratory/work areas that they supervise. Ensuring flammable liquids are used and stored in the smallest quantities necessary in the work areas that they supervise and that non-flammable, higher flash point, or less toxic materials are substituted for flammable liquids whenever possible. Ensuring appropriate PPE is available for work with flammable liquids. 5.3 The EHS Coordinator or Chemical Hygiene Officer is responsible for: Addressing questions or concerns regarding the use or storage of flammable liquids, and consulting with the EHS Office if necessary. Inspecting chemical storage areas, including the storage areas of flammable liquids, twice a year during Level II inspections and notifying the laboratory personnel and the PI/Supervisor of problems found so that they can be corrected or prevented. 5.4 The EHS Representatives are responsible for:

8 Page #: 8 of 11 Last Reviewed/Update Date: 5/20/13 Assisting the PI/Supervisors with the safe use and storage of flammable liquids in the work area. Specific duties may include periodically inspecting use and storage areas and keeping an inventory of flammable liquids. 5.5 Individuals using flammable liquids are responsible for: Knowing and following the storage rules for flammable liquids established in their laboratory/work area. Assuring that they have adequate training Using flammable liquids in accordance with training guidance provided. Reporting any incidents, problems or concerns with flammable liquids to their supervisor or the EHS Office. Wearing the PPE that is specified by their supervisor. 5.6 Contractors using, storing, or dispensing flammable liquids on MIT property are responsible for: Ensuring that a fire protection program (per NFPA and Cambridge Fire Department requirements) has been developed and implemented during all phases of demolition and construction Ensuring that flammable and combustible liquids are used and stored in accordance with generally accepted safety practices, as well as regulatory requirements. Ensuring that MSDS s are available upon request 6. Training All laboratory personnel working with flammable liquids must have completed General Chemical Hygiene Training (web-based or classroom) and Lab-Specific Chemical Hygiene Training. The Lab-Specific Chemical Hygiene Training, performed by a laboratory s PI or EHS representative shall include the following information if flammable liquids are used in the laboratory/work area: The hazards, safe use, and proper storage of flammable liquids. The location and function of specialized equipment needed for the safe use and storage of flammable liquids. Procedures to be used in case of an emergency with flammable liquids. The location of material safety data sheets (MSDS.) For non-laboratory personnel that use flammable liquids in their work area, the required training is General HAZCOM Training offered through the EHS Office. 7. Monitoring Requirements Work areas where flammable liquids are used and stored should be inspected at least twice a year during the Level II inspections. This is intended to help assure that the use and storage of flammable and combustible liquids are done in a safe and compliant manner.

9 Page #: 9 of 11 Last Reviewed/Update Date: 5/20/13 8. Records Management The DLC EHS Coordinator and the EHS Office shall maintain records of Level II inspections of storage areas containing flammable liquids. All records related to the use and storage of flammable liquids should be maintained per the Records Retention SOP. The EHS Office maintains permits and licenses for the storage and use of flammable and combustible liquids. 9. References The following references are available through the EHS Office: 9.1. Standards Massachusetts State Building Code 780 CMR Table 307.8(1) Massachusetts Board of Fire Prevention Regulations 527 CMR NFPA 30 - Flammable and Combustible Liquids Code NFPA 45 Fire Protection for Laboratories Using Chemicals OSHA Occupational Exposure to Hazardous Chemicals in Laboratories OSHA Flammable and Combustible Liquids 9.2. Other SOP/SOGs MIT EHS Office Liquid Petroleum Gas (Propane) SOP MIT EHS Office Compressed Gas SOP MIT EHS Office Chemical Storage SOP MIT EHS Office Records Retention EHS Office SOP MIT EHS Office Permit and License SOP MIT DOF Building Systems Design Handbook; Section Fume Hoods 9.3. Supplementary Documents MIT Environment, Health and Safety Policy MIT Hazard Communication (HAZCOM) Program MIT Chemical Hygiene Plan 9.4. Helpful Websites OSHA Regulations and Technical Manuals: Definitions Flammable Liquid is defined by the NFPA as a liquid having a Tag Closed Cup Flash Point of less than 100 F (38 C). These are known as Class I liquids and have been further classified as follows by NFPA: Class 1A: Liquids having flash points below 73 F and having a boiling point below 100 F. Class 1B: Liquids having flash points below 73 F and having a boiling point at or above 100 F. Class 1C: Liquids having flash points at or above 73 F and below 100 F.

10 Page #: 10 of 11 Last Reviewed/Update Date: 5/20/ Combustible Liquid is defined by the NFPA as a liquid having a Tag Closed Cup Flash point at or above 100 F. These are known as Class II or Class III liquids and have been further classified as follows by NFPA: Class II: Liquids having flash points at or above 100 F and below 140 F. Class IIIA: Liquids having a flash point at or above 140 F and below 200 F. Class IIIB: Liquids having a flash point at or above 200 F Flash Point - The lowest temperature of a liquid at which sufficient vapors are given off at the surface to form an ignitable mixture with air as determined by the Tag Closed Cup Method (ASTM D-56) Approved Storage Area A room or area, which has been specifically designated and designed including fire protection systems for the storage of flammable and combustible liquids. An approved storage area may not necessarily be approved for dispensing flammable liquids Approved Containers & Cabinets Equipment that is specifically approved and / or listed by Factory Mutual (or similar approval organization) or the Department of Transportation for use with flammable or combustible liquids Adequate Ventilation Exhaust ventilation that reduces the concentration of flammable vapors to the lowest practical levels during ordinary use. This includes general room ventilation as well as local or point of use exhaust including fume hoods Bonding & Grounding Connecting two or more conductive objects together by an electrical conducting wire and to a zero ground. The purpose of bonding and grounding is to eliminate any difference in electrical potential between the two objects and ground and therefore minimize the risk of a fire by a static- generated electrical spark.

11 Appendix A Example of Flammable Liquid Storage in Laboratories Example 1: Assume the building has a sprinkler system and all of the flammable liquids are Class IB (the most common class of flammable liquids in the laboratory.) There are six laboratories located on floor level 3 with doors having a 1-hour fire resistance rating and floors with a 2-hour fire resistance rating. Each lab is considered a distinct fire area since they have at least 1 hour fire resistance rating. Therefore, each lab can have a maximum of three flammable cabinets. Per Massachusetts Building Codes, only two control areas are allowed on floor level 3. Therefore, each control area will consist of three labs. The maximum amount of Class 1B liquids allowed on the floor is: 480 gals. if all are stored in approved flammable cabinets. The maximum amount of Class 1B liquids allowed on the floor is: 240 gals. if all are outside approved flammable cabinets. The amount allowed per control area (in flammable cabinets) e.g. a group of three labs, is 240 gals. Example 2: The same scenario above, but the labs are located on floor Level 4. The entire floor is one control area since the doors to the labs do not have a two-hour fire resistance rating. The maximum amount allowed on the floor is 6 gals. if they are stored in flammable cabinets.