flammable, combustible and toxic liquids-safe … · daimlerchrysler manufacturing technical...

DAIMLERCHRYSLER

MANUFACTURING TECHNICAL INSTRUCTIONS - SAFETY

SUBJECT:

FLAMMABLE, COMBUSTIBLE AND TOXIC LIQUIDS-SAFE STORAGE AND HANDLING OF

ISSUE DATE: 8/1/99

EFFECTIVE DATE: 10/11/2004

SERIES & NO.: SMI - 112

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DAIMLERCHRYSLER


Subject: FLAMMABLE, COMBUSTIBLE AND TOXIC LIQUIDS-SAFE STORAGE AND HANDLING OF

ISSUE DATE: 8/1/1999


REVIEW DATE: 10/11/2004

SERIES & NO: SMI - 112

1.0 PURPOSE

To instruct personnel relative to the procedure for the safe unloading and handling of Flammable, Combustible and Toxic Liquids in bulk form.

2.0 REFERENCE

• Manufacturing Technical Instruction – Safety SMI – 111 Instructions for the

Identification of Facility Piping Systems • Federal and State Occupational Safety and Health Acts • National Fire Prevention Association Codes • National Electric Codes • Stationary Environmental and Energy Bulletin SEB 601 “Environmental Emergency

Plan Requirements”

3.0 FUNCTIONS AFFECTED

Manufacturing Engineering Facilities Engineering Production Engineering Security & Fire Prevention Services Industrial Hygiene & Toxicology Employee Safety

4.0 OPERATIONS AFFECTED

DaimlerChrysler Corporation

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5.0 DEFINITIONS

5.1 Flash Point The flash point of a liquid corresponds to the lowest temperature at which the vapor pressure of the liquid is sufficient to produce a flammable mixture.

5.2 Flammable Liquids

A liquid having a flash point below 100 Deg. F (37.8 Deg. C) and having a vapor pressure not exceeding 40 psi absolute (2,068 mm Hg) at 100 Deg. F (37.8 Deg. C) shall be known as Class I liquids. Class I liquids shall be divided as follows: Class IA shall include those having flash points below 73 Deg. F (22.8 Deg. C) and having the boiling point below 100 Deg. F (37.8 Deg. C) Class IB shall include those having flash points below 73 Deg. F (22.8 Deg. C) and having the boiling point at or above 100 Deg. F (37.8 Deg. C)

Class IC shall include those having flash points at or above 73 Deg. F (22.8 Deg. C) and below 100 Deg. F (37.8 Deg. C)

5.3 Combustible Liquids

A liquid having a flash point at or above 100 Deg. F (37.8 Deg. C)

Combustible Liquids shall be subdivided as follows:

Class II liquids shall include those having a flash point at or above 100 Deg. F (37.8 Deg. C) and below 140 Deg. F (60 Deg. C)

Class IIIA liquids shall include those having a flash point at or above 140 Deg. F (60 Deg. C) and below 200 F (93 Deg. C)

Class IIIB liquids shall include those having flash points at or above 200 Deg. F (93 Deg. C)

5.4 Bonding Conductor

A bonding conductor is one, which serves to connect exposed metal surfaces together. 5.5 Grounding Conductor

A grounding conductor is one, which under normal conditions carries no current, but serves to connect exposed metal surfaces to an earth ground to prevent hazards in case of breakdown between current -conducting parts and the exposed surfaces. A grounding conductor may also

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be used to "bleed off" static electrical charge or lightning discharge from conductive surfaces of equipment or containers. The conductor may be bare or insulated. However, if it is insulated, the outer jacket shall be colored green with or without a yellow stripe.

5.6 Hazardous Substance

A chemical substance which because of its quantity, concentration or physical, chemical or infectious characteristics may pose an immediate or potential hazard to human health or the environment when improperly handled, stored transported or otherwise managed.

6.0 INFORMATION AND INSTRUCTIONS 6.1 Handling Precaution for Bulk Liquids

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6.1.1 Identification

A. Accidental mixture of flammable and combustible liquids shall be prevented. Gasoline mixed with fuel oil will reduce the flash point sufficiently to make it hazardous in ordinary use. Therefore, all exposed piping and valves carrying flammable liquids shall be identified by a color scheme, durable tags or markers, or a combination of all three. The identification shall indicate the DaimlerChrysler MS and/or NP numbers, the material name and the flash point classification.

Reference M.T.I. - Safety SMI-111 Arrows shall be used to indicate the flow of the liquid. Separate pumps shall be provided for different products.

B. Tanks containing flammable and combustible liquids shall be identified by having the

DaimlerChrysler MS and/or NP number and name painted on the tank in colors according to the Manufacturing Technical Instruction - Safety SMI-111, "Instructions for the identification of Piping Systems".

C. All filler pipes for flammable materials shall be painted RED NPVP-7.5R-4/14. On

attached identification sign painted with WHITE NPVP-N9.5 letters over Safety RED NPVP-7.5R-4/14 background shall indicate the material name, DaimlerChrysler MS and/or NP number and the tank capacity.

D. The words "FLAMMABLE" - "KEEP FIRE AWAY", shall be conspicuously painted in black

letters two or more inches in height on Safety Yellow background (NPVP -3.75Y 8.5/12) on all flammable liquid tanks and dikes.

6.2 Grounding

A. Static electricity can cause fires and explosions by discharging a spark of built-up electrical energy in the presence of flammable and/or explosive vapors. The greatest danger from the static spark is when the flammable vapors are present in the air; such as at the outlet of the fill pipe, delivery hose nozzle, open flammable liquid container or tank truck fill opening.

B. LIQUIDS SHALL NOT BE RUN INTO CONTAINERS UNLESS THE NOZZLE AND THE

CONTAINER ARE ELECTRICALLY CONNECTED BY SUITABLE GROUNDING. SEE Exhibits D & E for examples of suitable grounding.

C. Metallic portions of dispensing pumps, storage containers, metallic raceways and all

non-conducting portions of electrical equipment regardless of voltage, shall be grounded as provided in Article 250 of the National Electrical Code.

D. Grounding electrodes, conductors, and bonding conductors shall meet all requirements

set forth in Article 250 of the National Electrical Code. Refer to Exhibits "D" & "E".

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6.3 Safety Signs, Gauges and Equipment

A. Smoking or carrying "strike anywhere matches", lighters and other spark, or fire-producing devices is forbidden in areas where flammable liquids are handled or stored.

B. "No Smoking" signs or "Smoking, Carrying Matches, Open Lights, Positively Prohibited"

signs (White letters NPVP-N9.5 on Safety Red NPVP-7.5R 4/14 background) shall be posted conspicuously in areas where smoking and open lights are prohibited.

Signs made according to OSHA and NFPA standards for the Corporation and used by Pentagroup Graphic and Design Communications.

C. Each storage or receiving tank shall be equipped with hydrostatic gauges or other

suitable overflow prevention devices.

D. All filler pipes shall be equipped with locks that may be opened with a master key.

E. To minimize the danger of sparks, only non-ferrous safety tools shall be used in unloading areas. Leather faced, plastic and wood tools are free from sparks and friction. Other tools relatively free from spark hazard are those made from copper-beryllium, nickel, monel metal and bronze.

F. Government regulations require blue flag signs be placed at the ends of the approaches

to the railroad tank car while unloading operations are in process. The blue flag shall be placed at the siding locking switch or at the derailer. The sign shall be 12" x 15" or more in size and shall be worded as follows in black letters: "STOP - TANK CAR CONNECTED".

Each tank car unloading station for flammable liquids shall be protected by placing the derailer at least 100 feet from the station. The derailer (manually operated, padlocked type) shall be one manufactured by the Hayes or Track

Specialty Company or Staff Plant Engineering approved equal.

G. Spill equipment shall be readily available during loading and unloading operations.

6.4 Unloading Bulk Liquids From Tank Cars And Trucks 6.4.1 Preparation for Unloading

Security & Fire Prevention Services, Facilities Engineering, or functionally responsible activity shall be notified immediately when the tank car or tank truck containing bulk liquids arrive at the facility or plant.

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A. Security & Fire Prevention Services

- Shall accept only deliveries which are scheduled and arrive during normal working hours. Emergency deliveries will be accepted upon written consent of the Depot or Plant Manager and or availability of a Facilities Engineering or functionally responsible activity representative to monitor unloading.

- Directs tank truck or tank car to the proper unloading area and indicates disposal

point after confirmation with Facilities Engineering.

- Directs the tank truck driver to shut off engine of the motor vehicle, unless is used for the operation of a pump.

- Insures that the Safety Signs and Flags are properly posted and ground cables

are attached and that the equipment is free from leaks and other defects.

- Enforces applicable government fire prevention regulations for flammable liquids.

- If any unsatisfactory conditions are found, Security & Fire Prevention Services personnel will not authorize the unloading until such conditions have been corrected.

- Informs Facilities Engineering when safety conditions are satisfactory

B. Facilities Engineering

- Shall ensure that a DaimlerChrysler Representative is on site to monitor the

delivery and the unloading.

- The DaimlerChrysler representative shall determine the available capacity of the tank to be filled in order to prevent any overflow of spillage.

- Prior to attempting the transfer of a product, the delivery person shall be briefed

by the DaimlerChrysler representative as to the proper safety and unloading procedures.

- The DaimlerChrysler representative shall ensure that the liquid being delivered is

dispensed into the appropriate tank.

- Shall post the necessary safety signs and flags in the unloading zone or area, unless such signs have been permanently installed. The blue flags are to be placed at the ends of the approaches to the tank car.

- For tank cars - ensures that the brakes are set and the wheels blocked and then

connects the ground cable. For tank trucks - the above actions are monitored by the DaimlerChrysler representative and performed by the truck driver.

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- Ensures that repairs and repainting are performed where necessary on safety signs, filler caps, piping, valves and tanks. Ensures that grounding equipment is in good condition and free from corrosion at all times and maintains overflow protection devices and hydrostatic tank gauges.

6.4.2 Unloading

A. Unloading Tank Cars

After Security or the responsible person at the location indicates that the safety conditions are satisfactory, Facilities Engineering shall:

Open the top cover of the tank car for inspection and/or sampling of the material by the Receiving Department. Closes cover after inspection.

If top unloading -

- Reopen the tip cover and place the hose in the tank.

- Cover the top of the tank car opening with a Protect-o-seal Brand No. 2700 cover

or approved equivalent and unload the tank car.

- After the tank car is unloaded, remove the seal and the hose and close the cover.

If bottom unloading -

- Insure that the dump valve is closed.

- Remove the cap from the bottom of the car, and connect the hose to the car and filler pipes, open the top cover, cover top opening with a screen and release the dump valves.

- When the tank car is unloaded, remove the screen, hose, ground cable and any

portable signs, replace the top cover, tank car cap, filler pipe and close the dump valve.

- Verify that the tank car is empty and prepare it for its return.

B. Unloading Tank Trucks

After Security & Fire Prevention Services indicates that safety conditions are satisfactory, Facilities Engineering shall:

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Instruct the driver to remove a sample for approval test.

Check that the ground cable is attached properly.

After sample has been approved, instruct the driver to hook up the hose to storage tank and start unloading.

Monitor unloading to detect any leaks or overfilling.

When the storage tank is full or truck is empty, instruct the driver to shut off pump and remove hose and close valves.

Check truck to verify that it is empty.

Remove ground cable, close intake port into storage tank and remove any portable signs.

Release tank truck and inform Security & Fire Prevention Services that the tank truck has been released to leave the premises.

Authorize by signing the Vehicle Gate Pass, No. 84-241-0361, which is returned to the Security Gate person, upon leaving the plant.

NOTE: TANK CARS AND TRUCKS SHALL NOT BE ALLOWED TO STAND WITH THE HOSE CONNECTIONS ATTACHED AFTER UNLOADING IS COMPLETED. ALSO, TANK CARS AND TRUCKS SHALL NEVER BE LEFT UNATTENDED DURING UNLOADING.

6.4.3 Handling Spills During Unloading

A. Small Spills

- Operator will cut off the source of spill.

- On hard surface - flush off immediately. Liquids on the ground shall be instantly covered with sand or approved liquid absorbent. DO NOT ALLOW ENTRY INTO SEWERS - DIKE

- Inform Security & Management of the spill.

B. Large Spills

- Operator will cut off the source of the spill,

- By diking, control the flow of the spill. (note: facility personnel may only offer

defensive assistance.)

- Inform Security and Management about the spill so that the proper action will be taken per procedures noted in the Episode Plan.

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7.0 GENERAL SAFETY REQUIREMENTS 7.1 ALL PLANTS AND FACILITIES SHALL HAVE AN EMERGENCY EPISODE PLAN 7.2 All safety guidelines specified in this instruction shall be supervised and performed by trained &

qualified personnel. 8.0 EXHIBITS

- Drawing - Tank Car

- Drawing - Tank trucks and grounding clamps

- Drawing - Tank grounding

- Drawing - Grounding when filling containers from bulk storage

- Drawing - Grounding portable containers from bulk storage

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