Safe Use and Storage of

Flammable Liquids  

Strategies for Protecting Workers and Your Facility  

OSHA 1910.106, 1450 / 1926.152 Related Standards: 1910.1200, 1201

Flammable Liquid Landmines  

•  Common Errors Leading To BOOM! •  Using an unmarked container. •  Using an old anti-freeze or windshield wash jug. •  Carrying containers on back of the truck, unsecured,rough

handling, rag in spout. •  Carrying containers in passenger compartment. •  Using or carrying containers missing proper closure (caps). •  Filling containers on bed of truck. This can create static

electricity, esp. in low humidity.

“Pumping Gas”  

  NEVER leave the pump running unattended   Do NOT rely on the auto shut-off – especially at off-market locations   Keep nozzle in contact with tank fill pipe or container. This is grounding

discharge to dissipate static.   Shut off engine. Avoid using a cell phone while pumping gas   When exiting the vehicle, make sure to ‘touch metal’ to discharge static

electricity between you and the vehicle   Be alert for any ignition hazards in the area – i.e. smokers   Bonus Tip: carry a disposable glove or heavy grade tissue to handle the

icky pump nozzle   Gas weighs 6.3 lbs. per gallon. 5 Gal. can = 34 lbs. Less than water, but

still hefty.  

General ‘Best Practices’ For Flammable Handling  

  Check your storage and use areas for ignition sources.   For example, a bare lightbulb in a tool shed with gas cans is probably

not a good idea.   Electrical hardware must be approved for the location, i.e. vapor tight

fittings.   Make sure housekeeping is good- no trip hazards, spill control gear

handy, lighting adequate, sufficient clearances, not blocking aisles, no excess combustibles, etc. How far to nearest extinguisher?

  Check floor drains. Keep drain covers handy. Usually runs to a separator.

  Explain ‘primary’ and secondary containment.   Make sure your extinguishers are suited to the materials, properly sized,

etc.   Train, instruct, teach, demonstrate, show & tell, translated, etc. to be

sure employees understand the characteristics of the material, how to use extinguishers, explain HazCom, etc.

Definitions of Key Terms  

•  Flash point: the minimum temperature at which a liquid gives off vapor 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.

•  Combustible liquid: any liquid having a flash point at or above 100ºF.

OSHA- New Classes Of FL’s    Class I Flammable Liquid: has a flash point below

100ºF   Divided into three classes:   Class IA: liquids having flash points below 73ºF and a

boiling point below 100ºF   Class IB: liquids having flash points below 73ºF and a

boiling point at or above 100ºF   Class IC: liquids having flash points at or above 73ºF

and below 100ºF

Examples of Flammable Liquids  •  Class IA • Ether (starting fluid)

•  Class IB • Gasoline * Acetone • Ethanol • Alcohol

•  Class IC • Mineral spirits • Turpentine

Combustible Liquids  •  Combustible liquid: any liquid having a flash point at or above 100ºF

Combustible liquids are divided into two classes as follows:

•  Class II liquids: Flash points at or above 100ºF and below 140ºF •  Class III liquids shall include those with flash points at or above 140ºF •  Class III liquids are subdivided into two subclasses:

–  Class IIIA liquids: Flash points at or above 140ºF and below 200ºF

–  Class IIIB liquids - flash points at or above 200ºF  

Examples of Combustible Liquids  

•  Class II ‐ Diesel Fuel, Paint Thinner •  Class IIIA ‐ Home Heating Oil , Some

House Paint, Stains •  Class IIIB ‐ Cooking Oils, Lubricating Oils,

Motor Oil , Plain Old House Paint

FLAMMABLE (EXPLOSIVE) LIMITS      

•  When vapors of a flammable or combustible liquid are mixed with air in the proper proportions in the presence of a source of ignition, rapid combustion or an explosion can occur.

•  The proper proportion is called the flammable range or the explosive range. This range includes all concentrations of flammable vapor or gas in air, in which a flash will occur or a flame will travel if the mixture is ignited.

•  There is a minimum concentration of vapor or gas in air below which propagation of flame does not occur on contact with a source of ignition. There is also a maximum proportion of vapor in air above which propagation of flame does not occur.

•  These boundary-line mixtures of vapor with air are known as the lower and upper flammable limits (LFL or UFL) respectively, and they are expressed as their percentage by volume of vapor in air.  

Basic Chemistry of Fire  

•  Simple tri-lateral equation.

•  All three components must be present to create combustion.

What are LFL- UFL  

•  L = LOWER Flammable Limit (Not enough FUEL to ignite)

•  U = UPPER Flammable Limit ( TOO MUCH fuel to support ignition)

•  With gasoline for example, it does not take much vapor to reach the flammable range.

Define Your Purpose and Intended Use  

•  Incidental use – i.e. landscaping, mower and tool, equipment refueling

•  Production Process – i.e. paint spray booth, Body Shop

•  Bulk Storage – Tank Farms - Process Industries – Pipelines, etc.

•  Limit your on hand inventory as much as practicable.

Quantity is Your Determining Factor  •  60 gallons or more in one vessel is a storage TANK

•  Common small daily use containers are usually in the 1 to 5 gallon range

•  Larger quantities, i.e, 55 gallon drums will need special hardware – grounding lines, venting caps, self closing nozzles, etc.

•  Flammable liquid storage rooms need special engineering – Warning labels; protection class rated, berms on floor and at entrance, exhaust ventilation at floor and ceiling levels, FR doors and materials, unpainted walls, explosion resistant electrics, non-sparking hardware, alarms and sprinklers, among other controls

Limited Quantity Storage Cabinets  •  25 gal. or less does not need cabinet; i.e. spray

cans, incidentals •  Cabinets should be properly grounded •  Double walled, with air space, self extinguishing •  Vented, depending on contents, with fire baffle •  Self closing doors with latch engagement •  Internal door sill to prevent spillage •  Properly labeled – Pictorial Warning – “No Flame –

No Smoking” – Other Specific

OSHA 1926- Construction Standard  •  Not more than 60 gallons of Category 1, 2 and/or 3

flammable liquids or 120 gallons of Category 4 flammable liquids can be stored in one cabinet.

•  Not more than three cabinets may be located in a single storage area.

•  Quantities in excess of this must be stored in an inside flammable liquid storage room.

If  You  Use  FL’s  as  a  PROCESS,  You  Need  A  PROGRAM    •  Train  &  Equip  employees  for  the  correct  handling  &  exposures.  Have  a  wri?en  

protocol  in  your  safety  manual  describing  all  aspect  of  your  use  of  flammables:                                                                                                        Purchasing    Receiving    Transport    Storage    Handling    Dispensing    Recovery  of  spent  liquids    Disposal  or  recycling    Disposal  of  empty  containers    Health  monitoring  for  employees-­‐  industrial  hygiene    VenElaEon  systems  for  indoor  spray  applicaEons    Monitoring  for  concentraEons  of  vapor    Emergency  Response  &  Fire  –  i.e.  Industrial  Fire  Brigade  formaEon    

5 TONS of Flammable Product  

•  10,000 lbs. of any flammable liquid places you into the Highly Hazardous Chemical Standard

•  This triggers Process Safety Management Standard (PSM) compliance.

•  Your Occupancy Permit will trigger numerous levels of inspection – OSHA, State & Local, Insurance, Customer and others.

OSHA Process Safety Management Standard

(PSM)  

•  PSM is required reading for anyone using 10,000 lbs. of flammable liquids in a process environment.

•  The PSM Standard is a good tool to apply to any safety situation. It WORKS!

Process  Safety  Management  Standard  OSHA  1910.119  

This  is  a  very  important  standard,  possibly  one  of  the  most  far  reaching  in  all  of  OSHA’s  library.  We  can  learn  a  lot  from  it,  not  only  for  HHC’s  and  flammables  but  for  Safety  Program  Management  generally.  Among  the  more  salient  secEons:  •  Employee  ParEcipaEon  in  your  enEre  chemical  process  •  IniEal  Process  Hazard  EvaluaEon,  Pre-­‐Start  procedures  •  SOP’s,  wriVen  pracEces,  specificaEons,  i.e.  Hot  Work  Permits  •  ‘Management  of  Change’  descripEon,  responsibiliEes,  funcEonal  roles  •  Contractor  Safety  Management  •  ReporEng  of  Near  Miss  Events,  anomalies,  incident  invesEgaEons  •  Regular  review  &  update  of  the  safety  plan  •  hVps://www.osha.gov/pls/oshaweb/owadisp.show_document?p_table=STANDARDS&p_id=9760    

Gasoline CANS vs. Plastic Jugs  

•  The DOT regulates what can be carried on a vehicle. They do not look kindly on plastic jugs.

•  OSHA allows practically anything as long as it is compatible with the liquid.

•  Don’t be surprised if you get pulled over on a DOT roadside inspection and get cited for carrying a plastic gas jug, even though the OSHA guy didn’t write it up.

•  All containers MUST be clearly labeled with contents.

Safety  ‘Cans’  –  Some  are  High  Dollar    •  Depending  on  your  use,  you  may  need  

some  expensive  hardware.    •  General  Rule:  The  more  volaEle  the  

liquid,  the  more  complex  and  expensive  the  handling  &  hardware.  

•  For  example:  stainless  steel  cans,  self  closing,  baffled,  arrestor  spout,  raised  rim,  vented  can  easily  cost  over  $100.  You  want  to  be  sure  this  can  does  not  get  banged  around  carelessly  

•  Shop  cloth  &  towel  disposal  cans  •  Parts  washers  should  have  self  closing  lid  

on  a  fire  link,  although  most  solvents  have  been  changed  over  to  a  citrus  based  aqueous  fluid.    

Container Pictorial - GHS  

•  Unmistakable •  Universal •  Non-Verbal •  Easy to Recognize •  Required By OSHA & DOT •  Exxon SDS for Gasoline: •  www.msds.exxonmobil.com/IntApps/psims/SearchResults.aspx

Use of Burn Blankets  

•  Cool the burn quickly by removing heat from tissue

•  Avoid contamination of broken skin, bacteriostatic

•  Long shelf life •  Minimal inspection requirement •  Also can be used as an extinguishing

agent in some cases

How to Safely Dispense A Hazardous Liquid  

•  First, use ‘Engineering Methods’ to make the transfer as contained and safe as possible. Look for ways to eliminate need for pouring.

•  Position the containers and your body where you have good control over the pouring. Examples are trying to fill a chain saw on the ground. Use smallest container available.

•  Use a funnel or other hardware to be sure the liquid goes where you want it. Do not stand directly over the pour. Blowback.

•  Pour slowly. Avoid choking the funnel or spout, avoid backsplash, avoid vapor lock. Use vented containers for air pocket relief.

•  Wear eye protection, face shield, proper gloves, i.e. high grip, impervious. Keep a rag or towel handy for clean up.

•  Have an eye wash/shower in the area. Make sure it is functional. •  If you handle the liquids frequently, look for ways to improve,

minimize exposure

Extinguishers For Liquid Fires  

•  Dry Chemical A-B- C is most popular •  Water not recommended •  CO2 not recommended •  Aqueous foam will work, requires large

system •  Re- ignition is hazard

OSHA Lab Safety Standard 1910.1450  

•  Train employees, plan the work, minimize materials

•  Know how to react for clothing fire, small bench-top fire, when to call 911

•  https://www.osha.gov/Publications/laboratory/OSHA3404laboratory-safety-guidance.pdf

What  To  Look  For  On  INSPECTIONS    •  Fire  ExEnguisher,  mounted,  with  sign,  charged,  tagged,  dated  

•  Look  for  signs  of  liquid  leakage  or  spills.  Strong  odor  of  liquid  –  its  usually  smelly  stuff  

•  Sloppy  housekeeping,  tools  or  other  materials  impeding  access  •  Unlabeled  containers,  mongrel  containers,  incompaEble,  home  

made,  etc.  •  Improper  storage,  i.e.  cans  stacked  on  one  another,  foreign  objects  

that  could  cause  issues  •  DefecEve  or  open  electrical  boxes,  exposed  wiring,  unprotected  

bulbs,  etc.  •  Open  floor  drains;  eye  wash  or  shower;  burn  blanket;  first  aid  kit;  

spill  clean  up  kit;  PPE  handy  and  clean;  SDS’s  accessible;  other  specialty  hardware  such  as  non-­‐sparking  tools;  handing  equipment;  dedicated  pipelines  are  marked;  locaEon  of  shut  off  valves  are  marked;  venElaEon  is  operable  and  ductwork  is  clean;    

Know  the  CharacterisEcs  of  the  Liquid      Not  all  flammables  are  created  ‘equal’  

  Some  large  compressed  gas  boVles  for  example,  may  vent  to  atmosphere  at  a  certain  pressure.  

  Oxygen  and  fuel  gasses  on  torch  rigs  are  subject  to  have  a  separator  panel  on  the  cart.  

  Fuel  gas  boVles  must  be  stored  separately  from  Oxygen  boVles    Compressed  gas  cylinders  must  be  capped  and  stabilized  upright    Liquid  Propane  is  COLD,  need  to  use  insulated  glove  to  avoid  cold  

‘burn’.      Always  do  a  pressure  check  on  a  oxy-­‐fuel  gas  torch  rig.  Check  the  

TIP  –  if  it  is  damaged  or  clogged,  it  could  cause  an  explosion  in  the  torch  body  mixing  chamber.  Good  pracEce  is  to  always  use  a  new  Ep  or  carry  a  clean  spare  and  change  them  out.  A  bad  Ep  not  only  wastes  gas  but  gives  a  poor  cut.  It  could  also  cause  a  blockage  and  lead  to  an  explosion.    

John J. Meola, CSP, ARM Pillar, Inc. Safety Director

Richmond, VA

Mr.  Meola  has  many  years  experience  with  construcEon  and  industrial  safety  program  management.  He  is  a  published  author  and  contribuEng  writer  for  several  trade  

industry  magazines  and  the  World  Sweeping  AssociaEon.  His  consulEng  with  Pillar  Inc.  includes  transportaEon,  construcEon  and  industrial  safety  program  management.

He can be reached at: 804.283.0038

Jmeola@PillarENS.com www.pillarens.com