Hazardous Materials Handling

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<!-- image --> APPENDIX C TO §1910.119-COMPLIANCE GUIDELINES AND RECOMMENDATIONS FOR PROCESS SAFETY MANAGEMENT (NONMANDATORY) This appendix serves as a nonmandatory guideline to assist employers and employees in complying with the requirements of this section, as well as provides other helpful recommendations and information. Examples presented in this appendix are not the only means of achieving the performance goals in the standard. This appendix neither adds nor detracts from the requirements of the standard. - 1. Introduction to Process Safety Management. The major objective of process safety management of highly hazardous chemicals is to prevent unwanted releases of hazardous chemicals especially into locations which could expose employees and others to serious hazards. An effective process safety management program requires a systematic approach to evaluating the whole process. Using this approach the process design, process technology, operational and maintenance activities and procedures, nonroutine activities and procedures, emergency preparedness plans and procedures, training programs, and other elements which impact the process are all considered in the evaluation. The various lines of defense that have been incorporated into the design and operation of the process to prevent or mitigate the release of hazardous chemicals need to be evaluated and strengthened to assure their effectiveness at each level. Process safety management is the proactive identification, evaluation and mitigation or prevention of chemical releases that could occur as a result of failures in process, procedures or equipment.

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## Sections ## Subpart H -Hazardous Materials §1910.119 Process safety management of highly hazardous chemicals. APPENDIX A TO §1910.119-LIST OF HIGHLY HAZARDOUS CHEMICALS, TOXICS AND REACTIVES (MANDATORY) APPENDIX B TO §1910.119-BLOCK FLOW DIAGRAM AND SIMPLIFIED PROCESS FLOW DIAGRAM (NONMANDATORY) APPENDIX C TO §1910.119-COMPLIANCE GUIDELINES AND RECOMMENDATIONS FOR PROCESS SAFETY MANAGEMENT (NONMANDATORY) APPENDIX D TO §1910.119-SOURCES OF FURTHER INFORMATION (NONMANDATORY) ## Subpart I -Personal Protective Equipment §1910.132 General requirements. §1910.133 Eye and face protection. §1910.134 Respiratory protection. APPENDIX A TO §1910.134-FIT TESTING PROCEDURES (MANDATORY) APPENDIX B-1 TO §1910.134: USER SEAL CHECK PROCEDURES (MANDATORY) APPENDIX B-2 TO §1910.134: RESPIRATOR CLEANING PROCEDURES (MANDATORY) APPENDIX C TO §1910.134: OSHA RESPIRATOR MEDICAL EVALUATION QUESTIONNAIRE (MANDATORY) APPENDIX D TO §1910.134 (MANDATORY) INFORMATION FOR EMPLOYEES USING RESPIRATORS WHEN NOT REQUIRED UNDER THE STANDARD §1910.135 Head protection. §1910.136 Foot protection. §1910.137 Electrical protective equipment. §1910.138 Hand protection. ## Subpart J -General Environmental Controls §1910.145 Specifications for accident prevention signs and tags. §1910.146 Permit-required confined spaces. §1910.147 The control of hazardous energy (lockout/tagout). ## Subpart N -Materials Handling and Storage §1910.184 Slings.

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## Subpart H-Materials Handling, Storage, Use, and Disposal AUTHORITY: 40 U.S.C. 3701; 29 U.S.C. 653, 655, 657; and Secretary of Labor's Order No. 12-71 (36 FR 8754), 8-76 (41 FR [redacted postal code]), 9-83 (48 FR [redacted postal code]), 1-90 (55 FR 9033), 4-2010 (75 FR [redacted postal code]), or 1-2012 (77 FR 3912), as applicable. Section 1926.250 also issued under 29 CFR part 1911. ## §1926.250 General requirements for storage. - (a) General. (1) All materials stored in tiers shall be stacked, racked, blocked, interlocked, or otherwise secured to prevent sliding, falling or collapse. - (2) Maximum safe load limits of floors within buildings and structures, in pounds per square foot, shall be conspicuously posted in all storage areas, except for floor or slab on grade. Maximum safe loads shall not be exceeded. - (3) Aisles and passageways shall be kept clear to provide for the free and safe movement of material handling equipment or employees. Such areas shall be kept in good repair. - (4) When a difference in road or working levels exist, means such as ramps, blocking, or grading shall be used to ensure the safe movement of vehicles between the two levels. - (b) Material storage. (1) Material stored inside buildings under construction shall not be placed within 6 feet of any hoistway or inside floor openings, nor within 10 feet of an exterior wall which does not extend above the top of the material stored. - (2) Each employee required to work on stored material in silos, hoppers, tanks, and similar storage areas shall be equipped with personal fall arrest equipment meeting the requirements of subpart M of this part. - (3) Noncompatible materials shall be segregated in storage. - (4) Bagged materials shall be stacked by stepping back the layers and cross-keying the bags at least every 10 bags high. - (5) Materials shall not be stored on scaffolds or runways in excess of supplies needed for immediate operations. - (6) Brick stacks shall not be more than 7 f…

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Obey all local regulations for the disposal of liquids. ## Inhalation Illustration 51 <!-- image --> ## Exhaust Use caution. Exhaust fumes can be hazardous to your health. If you operate the machine in an enclosed area, adequate ventilation is necessary. ## Asbestos Information Cat equipment and replacement parts that are shipped from Caterpillar are asbestos free. Caterpillar recommends the use of only genuine Cat replacement parts. Use the following guidelines when you handle any replacement parts that contain asbestos or when you handle asbestos debris. Use caution. Avoid inhaling dust that might be generated when you handle components that contain asbestos fibers. Inhaling this dust can be hazardous to your health. The components that may contain asbestos fibers are brake pads, brake bands, lining material, clutch plates, and some gaskets. The asbestos that is used in these components is bound in a resin or sealed in some way. Normal handling is not hazardous unless airborne dust that contains asbestos is generated. If dust that may contain asbestos is present, there are several guidelines that should be followed: - · Never use compressed air for cleaning. - · Avoid brushing materials that contain asbestos. - · Avoid grinding materials that contain asbestos. - · Use a wet method in order to clean up asbestos materials. - · A vacuum cleaner that is equipped with a high efficiency particulate air filter (HEPA) can also be used. - · Use exhaust ventilation on permanent machining jobs. - · Wear an approved respirator if there is no other way to control the dust. - · Comply with applicable rules and regulations for the work place. In the United States, use Occupational Safety and Health Administration (OSHA) requirements. These OSHA requirements can be found in '29 CFR 1910.1001'. In Japan, use the requirements found in the 'Ordinance on Prevention of Health Impairment due to Asbestos' in addition to the requirements of the Industrial Safety and Health Act.…

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## Subpart H-Hazardous Materials AUTHORITY: Sections 4, 6, and 8 of the Occupational Safety and Health Act of 1970 (29 U.S.C. 653, 655, 657); Secretary of Labor's Order No. 12-71 (36 FR 8754), 8-76 (41 FR [redacted postal code]), 9-83 (48 FR [redacted postal code]), 1-90 (55 FR 9033), 6-96 (62 FR 111), 3-2000 (65 FR [redacted postal code]), or 5-2007 (72 FR [redacted postal code]), 4-2010 (75 FR [redacted postal code]) or 1-2012 (77 FR 3912), as applicable; and 29 CFR part 1911. Sections 1910.103, 1910.106 through 1910.111, and 1910.119, 1910.120, and 1910.122 through 1910.126 also issued under 29 CFR part 1911. Section 1910.119 also issued under Section 304, Clean Air Act Amendments of 1990 (Pub. L. 101549), reprinted at 29 U.S.C.A. 655 Note. Section 1910.120 also issued under Section 126, Superfund Amendments and Reauthorization Act of 1986 as amended (29 U.S.C.A. 655 Note), and 5 U.S.C. 553. ## §1910.119 Process safety management of highly hazardous chemicals. Purpose. This section contains requirements for preventing or minimizing the consequences of catastrophic releases of toxic, reactive, flammable, or explosive chemicals. These releases may result in toxic, fire or explosion hazards. - (a) Application. (1) This section applies to the following: - (i) A process which involves a chemical at or above the specified threshold quantities listed in appendix A to this section; - (ii) A process which involves a Category 1 flammable gas (as defined in 1910.1200(c)) or a flammable liquid with a flashpoint below 100 °F (37.8 °C) on site in one location, in a quantity of 10,000 pounds (4535.9 kg) or more except for: - (A) Hydrocarbon fuels used solely for workplace consumption as a fuel (e.g., propane used for comfort heating, gasoline for vehicle refueling), if such fuels are not a part of a process containing another highly hazardous chemical covered by this standard; - (B) Flammable liquids with a flashpoint below 100 °F (37.8 °C) stored in atmospheric tanks …

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## 29 CFR 1910 (OSHA) in starting up or shutting down the process. In these cases, different parameters will be required from those of normal operation. These operating instructions need to clearly indicate the distinctions between startup and normal operations such as the appropriate allowances for heating up a unit to reach the normal operating parameters. Also the operating instructions need to describe the proper method for increasing the temperature of the unit until the normal operating temperature parameters are achieved. Computerized process control systems add complexity to operating instructions. These operating instructions need to describe the logic of the software as well as the relationship between the equipment and the control system; otherwise, it may not be apparent to the operator. Operating procedures and instructions are important for training operating personnel. The operating procedures are often viewed as the standard operating practices (SOPs) for operations. Control room personnel and operating staff, in general, need to have a full understanding of operating procedures. If workers are not fluent in English then procedures and instructions need to be prepared in a second language understood by the workers. In addition, operating procedures need to be changed when there is a change in the process as a result of the management of change procedures. The consequences of operating procedure changes need to be fully evaluated and the information conveyed to the personnel. For example, mechanical changes to the process made by the maintenance department (like changing a valve from steel to brass or other subtle changes) need to be evaluated to determine if operating procedures and practices also need to be changed. All management of change actions must be coordinated and integrated with current operating procedures and operating personnel must be oriented to the changes in procedures before the change is made. When the process is shut down in or…

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## M. DISPOSAL OF HAZARDOUS WASTE Dispose of waste oils, fluids, lubricants, filters and other hazardous waste properly. <!-- image --> <!-- image --> ## CONTAMINATION HAZARDS Dispose of all hazardous waste in accordance with government environmental laws and regulations. ## N. SEALS AND O-RINGS After removing the O-ring or gasket, clean the seal surface, and replace with a new one. Always replace seals and O-rings with new parts. Never reuse a seal or O-ring during reassembly of components. Lubricate all new seals with the appropriate oil before installation. ## O. USE SUPPORT EQUIPMENT DURING SERVICE When machine inspection or maintenance is done under the boom, arm or under the bucket/attachment use proper equipments or blocks to secure the attachment. <!-- image --> ## P. CAUTION WHILE CHANGING BUCKET/ATTACHMENT Do not insert your finger, hand or arm into the pin bore. The alignment must be carried out visually or by using a tool. <!-- image --> <!-- image -->

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## 29 CFR 1910 (OSHA) - (6) At least every five (5) years after the completion of the initial process hazard analysis, the process hazard analysis shall be updated and revalidated by a team meeting the requirements in paragraph (e)(4) of this section, to assure that the process hazard analysis is consistent with the current process. - (7) Employers shall retain process hazards analyses and updates or revalidations for each process covered by this section, as well as the documented resolution of recommendations described in paragraph (e)(5) of this section for the life of the process. - (f) Operating procedures (1) The employer shall develop and implement written operating procedures that provide clear instructions for safely conducting activities involved in each covered process consistent with the process safety information and shall address at least the following elements. - (i) Steps for each operating phase: - (A) Initial startup; - (B) Normal operations; - (C) Temporary operations; - (D) Emergency shutdown including the conditions under which emergency shutdown is required, and the assignment of shutdown responsibility to qualified operators to ensure that emergency shutdown is executed in a safe and timely manner. - (E) Emergency Operations; - (F) Normal shutdown; and, - (G) Startup following a turnaround, or after an emergency shutdown. - (ii) Operating limits: - (A) Consequences of deviation; and - (B) Steps required to correct or avoid deviation. - (iii) Safety and health considerations: - (A) Properties of, and hazards presented by, the chemicals used in the process; - (B) Precautions necessary to prevent exposure, including engineering controls, administrative controls, and personal protective equipment; - (C) Control measures to be taken if physical contact or airborne exposure occurs; - (D) Quality control for raw materials and control of hazardous chemical inventory levels; and, - (E) Any special or unique hazards.

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## 29 CFR 1910 (OSHA) If the employer wants specific employees in the release area to control or stop the minor emergency or incidental release, these actions must be planned for in advance and procedures developed and implemented. Preplanning for handling incidental releases for minor emergencies in the process area needs to be done, appropriate equipment for the hazards must be provided, and training conducted for those employees who will perform the emergency work before they respond to handle an actual release. The employer's training program, including the Hazard Communication standard training is to address the training needs for employees who are expected to handle incidental or minor releases. Preplanning for releases that are more serious than incidental releases is another important line of defense to be used by the employer. When a serious release of a highly hazardous chemical occurs, the employer through preplanning will have determined in advance what actions employees are to take. The evacuation of the immediate release area and other areas as necessary would be accomplished under the emergency action plan. If the employer wishes to use plant personnel such as a fire brigade, spill control team, a hazardous materials team, or use employees to render aid to those in the immediate release area and control or mitigate the incident, these actions are covered by §1910.120, the Hazardous Waste Operations and Emergency Response (HAZWOPER) standard. If outside assistance is necessary, such as through mutual aid agreements between employers or local government emergency response organizations, these emergency responders are also covered by HAZWOPER. The safety and health protections required for emergency responders are the responsibility of their employers and of the onscene incident commander. Responders may be working under very hazardous conditions and therefore the objective is to have them competently led by an on-scene incident commander and the comm…