Put the Lid on Flammable Liquid Hazards (1910.106)

Do your employees know how to properly store, transfer, and dispose of flammable liquid hazards?

By Elaine Quayle

Contents:
Storing flammable liquids
Handle with care
Employee education
Training tips

A few years ago, an explosion and fire ripped through a chemical plant in Lodi, NJ, killing four workers and injuring nine, while completely demolishing the facility. Investigation revealed that the improper mixing of flammable chemicals in a reactor vessel was to blame.

Incidents such as this one are, unfortunately, not that uncommon.

Statistics indicate that over 21 percent of industrial fires and 15 percent of office fires start with the ignition of a flammable or combustible liquid. What makes these substances so hazardous?

Flammable liquids burn at relatively low temperatures (under 100 degrees Fahrenheit), making them susceptible to catching fire or exploding when set off by even the smallest spark. Some factors that can contribute to these accidents include:

• Improper container storage.
  
• Lack of bonding and grounding procedures.
  
• Lack of control of ignition sources, particularly during maintenance and contractor activities.
  
• No hot work permits and procedures.
  
• Inadequate employee training in handling and disposing of flammable liquids and in emergency response techniques.

Storing flammable liquids

Essential steps in a flammable liquid safety program are reducing the amount of chemicals in storage and in the work area and disposing of materials that are no longer needed. Your company should define a specific limit on the amount of flammable liquids that can be stored on-site at any given time.

Isolating the storage area for 55-gallon drums is the ideal method for keeping fire hazards away from the general work areas. If it is not possible to use a separate storage building, then a two-hour fire wall with 1 1/2-hour fire doors should be constructed to contain the storage area. The area should be diked, and floor drains must not empty into the common sanitary drains.

OSHA Required Training for Flammable and Combustible Liquids 1910.106
(b)(5)(v) 2 and 3. OSHA regulations require:

• That detailed printed instructions of what to do in flood emergencies are properly posted.
  
• That station operators and other employees depended upon to carry out such instructions are thoroughly informed as to the location and operation of such valves and other equipment necessary to effect these requirements.

Small containers of flammable liquids, such as paint spray cans, thinners, and solvents, should be stored in special cabinets.

Flammables should always be kept in approved safety containers that have vapor-tight caps and flame arresters. Make sure the containers are labeled and in good condition. Always store flammable liquids in a well-ventilated, temperature-controlled area.'
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Handle with care

Special procedures must be used when transferring flammable liquids from one container to another. You want to avoid any static electricity during the process. Make sure the drum containing the liquid is grounded. Then, connect the drum to the transfer container with a bonding wire.

The best way to avoid a buildup of vapors in the air is to thoroughly ventilate the work area. Make sure there is enough fresh air to clean the vapors out. Areas surrounding the work area should be sealed off or ventilated as well. The work area should have special sparkproof light switches and fixtures.

The same principle of ventilation applies to empty drums that once contained flammable liquids. All it takes is a few drops left over to form an explosive mixture with the air in the drum. Never allow your employees to do repair work or weld on a drum without steaming it out first.
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Employee education

Employees must be taught about the properties of flammable liquids. For example, they need to know that the liquid itself doesn't burn, but rather its invisible vapors. These vapors are heavier than air and will settle near the floor. They are especially dangerous because they can't be seen or detected by smell. That's why handling, storage, and disposal must be done carefully to prevent ignition.

Make your employees aware of the ignition sources in your workplace that could cause an explosion or fire, such as electrical switches, open motors, static electricity, radiant heat, friction and mechanical sparks, heat guns, and cutting and welding activities.

Workers also should be thoroughly trained on how to handle a fire or spill. A complete emergency response plan should cover all flammable liquids on site. The use of proper personal protective equipment must be emphasized.

Show your workers how to safely dispose of flammable liquids. Don't just pour them into a drain, sewer, garbage can, or on the ground. Read the material safety data sheet (MSDS) for instructions on how to safely dispose of the liquids. If your employees spill any on themselves, they should follow proper procedures for decontamination as indicated on the MSDSs. Other important training topics include:

• Housekeeping requirements.
  
• Fire alarm and suppression systems.
  
• Warning sign requirements.

Training tips

Hold a contest to see who can name the most flammable liquids at your worksite. Review the MSDSs and labels for some of these liquids and discuss safety procedures during usage. Rehearse emergency procedures during a spill or explosion.

Start off right by providing every new worker with instructions for handling flammable liquids. Then provide an on-going training program when new or different flammable liquid handling, equipment, or procedures are changed. By keeping up with your training program, you and your employees will feel confident about handling these useful, but potentially dangerous, substances.

About the author: Elaine Quayle is the editor of the newsletter titled "OSHA Required Training for Supervisors," which is published by BLR-Business & Legal Reports, Inc.
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