Dangerous Gas Standard

Transcription

1 Dangerous Gas Standard Purpose The purpose of this standard is to establish the minimum standards required for researchers at Clemson University that utilize dangerous gases (i.e., toxic, highly toxic, flammable, pyrophoric and corrosive). This standard will reduce the likelihood of a dangerous gas release and ensure the safety of laboratory researchers, building occupants, and emergency responders to gas leak events or other emergencies. Definitions Dangerous gases include any gases that may cause significant acute health effects at low concentration. For purposes of this standard, dangerous gases means toxic, highly toxic, corrosive, flammable and pyrophoric gases with any of the following specific characteristics: National Fire Protection Association (NFPA) health hazard rating of 3 or 4; NFPA health hazard rating of 2 with poor physiological warning properties; Extremely low occupational exposure limits in the absence of an NFPA health rating; or Pyrophoric (self-igniting) characteristics. Pyrophoric, flammable, corrosive, toxic and highly toxic gases can be further defined: Pyrophoric Gas that upon contact with air or oxygen, will ignite spontaneously at or below a temperature of 54.4 degrees C (130 degrees F). Toxic Gas with an LC50 in air of more than 200 ppm, but not more than 2000 ppm by volume of gas or vapor, when administered by continuous inhalation for one hour (or less if death occurs within one hour) to albino rats weighing between 200 g and 300 g each. Highly Toxic Gas with an LC50 in air of 200 ppm by volume or less of gas or vapor when administered by continuous inhalation for one hour (or less if death occurs within one hour) to albino rats weighing between 200 g and 300 g each. Corrosive A gas that causes visible destruction or irreversible alterations in living tissues by chemical action at the site of contact. It may be acidic or alkaline.

2 Flammable Gas A material which is a gas at 68 F (20 C) or less at 14.7 pounds per square inch atmosphere (psia) (101 kpa) of pressure [a material that has a boiling point of 68 F (20 C) or less at 14.7 psia (101 kpa)] which: 1. Is ignitable at 14.7 psia (101 kpa) when in a mixture of 13 percent or less by volume with air; or 2. Has a flammable range at 14.7 psia (101 kpa) with air of at least 12 percent, regardless of the lower limit. The limits specified shall be determined at 14.7 psi (101 kpa) of pressure and a temperature of 68 F (20 C) in accordance with ASTM E 681. For a list of dangerous gases including NFPA health hazard rating and properties see Appendix 1. Minimum Threshold Quantities Minimum Threshold Quantities are as follows: DOT Poison-A (highly toxic) o ¼ lb per cylinder and less than 1 lb total Other Dangerous Gases o 1 lb per cylinder and less than 2 lb total Dangerous Gas Review and Approval Procedure 1. Complete and submit a Pre-Operational Safety, Health and Environmental Review (POSHER) form to Research Safety Complete and submit a Standard Operating Procedure (SOP) for Dangerous Gas Use to Research Safety. This document at a minimum should include the following information: a. Gas type/concentration/volume stored in cylinder-temperatures/pressures expected at various points in the process b. Apparatus safety features (restricted flow orifice (RFO) size, excess flow valves, shutoff valves, etc.) c. Piping/material/size/anchorage/route to be used from cylinder to point of use d. Dedicated exhaust used for tool (e.g. certified fume exhaust, gas cabinet, special purpose hood/enclosure) e. Details regarding cylinder installation (e.g. how it will be secured) f. Leak check procedures for piping systems prior to opening gas valve and when receiving cylinder(s) g. Information regarding monitoring systems and alarms in place

3 h. Description of any other collateral hazards (e.g. lasers, electrical) i. Each lab should have documentation of cylinder change out procedure as part of the SOP. 3. Research Safety will coordinate a Code review, approval and signoff from the appropriate Code Official (Facilities Services and Fire Marshal) Note: This may not be necessary for small quantities of a toxic gas in a lecture bottle. The Director of Research Safety will provide final approval and signoff of the POSHER once all safety requirements are met. Responsibilities Principal Investigator Maintain primary responsibility for dangerous gas safety in the laboratory. Designate and address the use of dangerous gases as part of a standard operating procedure (SOP) (see SOP template). Ensure the gas inventory is updated with correct names and quantities of dangerous gases. Ensure gases are secured and stored properly at all times. Check that dangerous gas cylinders received from vendors are equipped with gas tight dust caps on the cylinder gas outlet and cylinder safety caps to protect the gas cylinder valve during transit. This should be provided by the vendor. If dangerous gas cylinders are received without required cylinder safety caps contact Research Safety who will follow-up with the vendor. Provide training to laboratory personnel that utilize dangerous gases and document training. Ensure that laboratory personnel are compliant in following the Clemson Dangerous Gas Standard. Ensure that required gas monitors are calibrated and replace sensors based on manufacturer specifications. Records must be accessible to Research Safety as part of lab safety reviews. (Note: this may be provided and maintained by Facilities Services or the site facility management.) Ensure operation and maintenance of any dangerous gas engineering controls.

4 Notify adjacent labs of dangerous gas use and risks. Research Safety will assist researchers in the coordination and communication about dangerous gas use in the facility. Comply with any required conditions of the approved Pre-Operational Safety, Health and Environmental Review (POSHER) form. Laboratory Employees Review and follow proper work practices as identified by the approved POSHER, lab specific SOP and the Clemson Dangerous Gas Standard. Verify that dangerous gases are always used and stored in properly exhausted enclosures. Understand and properly respond to monitoring alarms. The Office of Research Safety Assist researchers in developing safe lab operations utilizing dangerous gases. Implement the Clemson Dangerous Gas Standard. Review and approve a Pre-Operational Safety, Health and Environmental Review (POSHER) form for dangerous gas use. Review and approve dangerous gas delivery system design prior to construction. Review and approve dangerous gas SOPs Periodically review the lab safety practices for dangerous gas use Annually review and update the Clemson Dangerous Gas Standard. Inform emergency responders (CUFD, CU Police) on dangerous gas locations and emergency response plans for dangerous gas lab spaces. Assist in response to alarms related to dangerous gas systems. General Guidance for the Use of Dangerous Gases Office of Research Safety approval: Use of dangerous gases requires a Pre-Operational Safety, Health and Environmental Review (POSHER) approval form signed by the Director or Research Safety or designee prior to the start of work. Notification to Research Safety is also required if there are significant changes in procedures or quantities of hazardous gases used in a specific laboratory.

5 CGA: Compressed Gas Association: A trade organization that promotes industry standards for manufacture, storage, transportation and use of compressed gases. The CGA sets standards for cylinder valve outlet connections. Ventilation: Proper ventilation is required in laboratories using dangerous compressed gases. The presence of a fume hood is mandatory (except for oxygen use) unless a gas cabinet and special local exhaust system or filtering system is used. Contact Research Safety to determine if your lab has a ventilation system appropriate for hazardous gas use before purchasing the gas. Specialty ventilation systems such as gas cabinets and locally exhausted enclosures may also be required. Cylinder Size: Use lecture-sphere or bottle-size dangerous gas sources in a returnable cylinder when small volumes are needed. While the initial purchase cost per cubic foot may be lower when hazardous gases are purchased in full-sized cylinders, the overall cost of experimental setup, which may require local ventilation, gas cabinets, stainless steel piping and purging systems may off set the apparent saving from buying hazardous gases in full-sized cylinder quantities. Cylinder holders: All compressed gas cylinders, regardless of size, must be properly secured. Use floor or bench clamps or secure gases to the wall with chains installed by Facilities Services. A single floor or bench clamp may not be used to secure multiple cylinders unless it is designed for multiple cylinder support. Regulators: Gases from full-sized gas cylinders must be dispensed using a two-stage regulator, with a tied diaphragm that is both compatible with the gas and the intended use. A two-stage regulator is a device that reduces the higher pressure in the gas cylinder to a lower working pressure. Two-stage regulators control pressure in two steps allowing precise control of pressure. The maximum pressure of the second stage of the regulator should be as low as is practical for the intended experimental work. Do not select or reuse existing regulators with very high second stage pressure ranges unless needed, since this will require the entire experimental setup (tubing, connections) to be engineered to withstand high pressures. Flow control valves: A mechanical flow control valve (needle valve) that is compatible and properly cleaned for the hazardous gas must be attached directly to the gas out port of the gas regulator. This is required even if other flow control devices are present in the experimental device. Flow control must not be attempted through use of the gas regulator. Flow restricting orifices: Where feasible flow restricting devices must be installed after the regulator. Select the appropriate flow restricting orifice based on gas used and the flow rate required for the research. Tubing and piping: Hazardous gases must be dispensed using systems that are properly cleaned and compatible with the gas in use. Burst pressure of tubing and piping must exceed the maximum pressure on the second stage regulator. Exceptions to this requirement may be made for short sections of tubing when it and the compressed gas cylinder are completely enclosed in a fume hood and low pressures and flow rates are used.

6 Purge assembly: Required for all hazardous gas systems that are not used in a fume hood or other ventilated enclosure. Purge assemblies must exhaust into a fume hood or other approved exhaust system. Exceptions may be made for laser systems that contain small quantities of hazardous gas that will be effectively filtered when exhausted. Exemptions must be approved by Research Safety. Vacuum pumps: Hydrocarbon based vacuum pump oil is incompatible with strongly oxidizing and many reactive gases. New vacuum pumps that have inert lubricants such as Chemours Krytox and never contained oil-based lubricants must be used with oxidizing and reactive gases. Vacuum pumps must be securely vented to a fume hood or other approved exhaust system with tubing that is compatible with the gases used. Exhaust lines must be as short as feasible. Vented enclosures may be required for vacuum pumps depending on the toxicity of the gases used. Leak testing: Hazardous gas systems must be leak tested using inert gas and leak detection solutions such as Snoop before use. Helium leak testing for all lines conveying highly toxic gases may also be required. Designated area The room sign for the laboratory must contain an identifier where highly toxic and dangerous gases are used or stored. All locations within the laboratory where highly toxic and dangerous gases are handled should be demarcated and/or posted with designated area caution signs. Emergency procedure Emergency procedures which address response actions to fires, explosions, spills, injury to staff, or the development of signs and symptoms of overexposure must be developed. The procedures should address at a minimum the following: Hazard assessment 1.) Who to contact: (Clemson Fire Department, Clemson Police, Research Safety, Principal investigator of the laboratory including evening phone number). 2.) The location of all safety equipment (showers, eye wash, fire extinguishers, etc.) 3.) The method used to alert personnel in nearby areas of potential hazards. The response procedure to any alarm systems that are utilized. 4.) Special first aid treatment required by the type of highly toxic material(s) handled in the laboratory. Hazard assessment should focus on the education of employees concerning the health risk posed by dangerous gases, on proper use and handling procedures, the demarcation of designated areas, and emergency evacuation and notification procedures in the event of a gas release.

7 Safety shielding Safety shielding is required any time there is a risk of explosion, splash hazard or a highly exothermic reaction. All manipulations of dangerous gases which pose this risk should occur in a fume hood with the sash in the lowest feasible position. Portable shields, which provide protection to all laboratory occupants, are acceptable. Eyewash and Safety shower An eyewash and safety or drench shower must be available in a nearby location where the dangerous gases are used. Check to ensure the eyewash and safety or drench shower BEFORE each use when dangerous gases will be used. Containers All dangerous gas cylinders must be clearly labeled with the correct chemical name. Handwritten labels are acceptable; chemical formulas and structural formulas are not acceptable. A label for highly toxic gases is available. All labels must meet Global Harmonization Standards. Special storage Highly toxic and dangerous gases must be stored in a designated area. The quantity of a highly toxic and dangerous gas that may be stored in a laboratory will be determined by the applicable building and fire code and reviewed by the Office of Research Safety and the Clemson Fire Marshall or appropriate code official. Storage and use areas should be secured against unauthorized entry. Cylinders All dangerous gas cylinders should have a restricted flow orifice installed in the cylinder valve outlet that limits the maximum gas release rate during an accidental release scenario. All dangerous gas cylinders should be located within a ventilated gas cabinet or laboratory fume hood. Ventilated cabinets must meet the following requirements: Located in a room or area which has independent exhaust ventilation Operate at negative pressure in relation to the surrounding area Have self-closing limited access ports or noncombustible windows to provide access to equipment controls, with an average face velocity of at least 200 fpm and with a minimum of 150 fpm at any part of the access port or window Connected to an exhaust system. Have self-closing doors and are constructed of at least inch (12 gauge) steel. Internally sprinklered, (if required), with an appropriate suppression agent.

8 Anchored Contain no more than 3 compatible dangerous gas cylinders per gas cabinet unless cylinder contains less than 1 lb of net contents. Special ventilation Special ventilation of the stored cylinders is required and must be approved by the Office of Research Safety and the Clemson Fire Department. Exhausted enclosures must meet minimum flow rates defined by code. Manipulation of highly toxic and dangerous gases outside of a fume hood, gas cabinet or exhausted enclosure will require prior approval and special ventilation controls in order to minimize exposure to the material. If your research does not permit the handing of dangerous gases in an approved fume hood, gas cabinet or exhausted enclosure, you must contact the Office of Research Safety to review the adequacy of the ventilation. Gas Detection System Continuous monitoring devices which will alert staff of a release of the acutely toxic and dangerous gas are required for certain gases. The Office of Research Safety has developed a written Gas Monitoring Program for reference. The detection system should initiate a local visual and audible alarm and where possible transmit a signal to a constantly attended location. Activation of the monitoring system should automatically close the emergency shut-off valve on dangerous gas supply lines to the system being monitored. Gas monitoring sensor ports should be located inside the ventilated cabinet, near the equipment and in the lab operator area. An alarm status and gas concentration read out should be located outside the gas use room or be visible through a window. Gas detection may also be necessary to monitor exhaust flow rates, excess gas flow rates and other controls as defined by code or safe practice. Refer to the Clemson University Gas Monitoring Document for further information on Gas Detection and Monitoring requirements. Spill response In the event of escape of gas or gas alarm, alert personnel in the area that a release has occurred. Do not attempt to handle a release of acutely toxic or dangerous gases. Vacate the laboratory immediately and call 911 for assistance. Waste disposal All empty or partially filled dangerous gas cylinders should be returned to the supplier. If the supplier does not accept empty or partially filled cylinders, contact the Office of Research Safety concerning appropriate disposal.

9 Other All chemical fume hoods or gas cabinets must have a ventilation monitor that measures duct or enclosure exhaust performance. This monitor should be tied into an alarm to notify users if ventilation fails or falls below a pre-determined set point. Emergency power should be provided for exhaust ventilation, gas detection systems, emergency alarm systems and temperature control systems. In the event of a power failure, the detection system should continue to operate without interruption or gas systems should automatically shut down at the source. An approved, supervised smoke detection system shall be provided in rooms or areas were dangerous gases are stored indoors. Storage and use areas should be secured against unauthorized entry. Only qualified personnel should perform dangerous gas cylinder change out. Each lab should have documentation of cylinder change out procedure as part of the SOP. All empty dangerous gas cylinders should be labeled as Empty and be returned to the vendor for disposal. If a vendor will not accept a cylinder or an older or compromised cylinder is found, contact Research Safety for an assessment and to arrange disposal. All users, lab occupants and emergency responders should be trained and know how to respond in the event of a dangerous gas leak. References University of North Carolina, EH&S, Laboratory Design Guidelines University of Pennsylvania, Environmental Health and Radiation Safety, Hazardous and Highly Toxic Gases Stanford University, Toxic Gas Standard Operating Procedures North Carolina State, EH&S, Gas Monitoring Program International Fire Code, IFC 2012 Edition NFPA 1, Chapter 3, 2012 Edition NFPA 45, Chapter 8 NFPA 55, Chapter 3 NFPA 704, Chapter 5 ANSI/CGA-G Edition -- (American National Standards Institute / Compressed Gas Association) Storage and Handling of Silane and Silane Mixtures.

10 List of Common Dangerous Gases (CAS#) Ammonia ( ) Arsenic pentafluoride ( ) Arsine ( ) Boron Tribromide ( ) Boron Trichloride ( ) Boron Trifluoride ( ) Bromine ( ) Bromine pentafluoride ( ) Bromine trifluoride ( ) 1,3 butadeine ( ) Carbon tetrafluoride ( ) Carbon monoxide ( ) Carbonyl fluoride ( ) Carbonyl sulfide ( ) Chlorine ( ) Chlorine dioxide ( ) Chlorine trifluoride ( ) Cyanogens ( ) Cyanogen chloride ( ) Diborane ( ) Dichlorosilane ( ) Dimethylamine ( ) Fluorine ( ) Germane ( ) Hydrogen bromide ( ) Hydrogen chloride ( ) Hydrogen cyanide ( ) Hydrogen fluoride ( ) Hydrogen selenide ( ) Hydrogen sulfide ( ) Methyl bromide ( ) Methyl fluoride ( ) Methylisocyanate ( ) Nickel carbonyl ( ) Nitric oxide ( ) Nitrogen dioxide ( ) Nitrogen trifluoride ( ) Phosgene ( ) Phosphine ( ) Phosphorus oxychloride ( )

11 Phosphorus pentafluoride ( ) Phosphorus trichloride ( ) Phosphorus trifluoride ( ) Selenium Hexafluoride ( ) Silane ( ) Silicon tetrachloride ( ) Silicon tetrafluoride ( ) Stibine ( ) Sulfuryl fluoride ( ) Tellurium hexafluoride ( ) Titanium tetrachloride ( ) Trichlorosilane ( ) Trimethyl aluminum ( ) Trimethyl boron ( ) Trimethyl gallium ( ) Tungsten hexafluoride ( ) Vinyl chloride ( )