BASF Flash Fire FRC Assessment Tool

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1 BASF Flash Fire FRC Assessment Tool Introduction The assessment tool offered in this document was developed to assist BASF manufacturing units in evaluating the potential for flash fire occurrence and determination of the need for supplemental worker protection through the use of flame resistant clothing (FRC). Flash fire hazards may exist in work areas where flammable materials are handled, processed, stored, or in any way present. The most common definition of flash fire is a fire that spreads rapidly through a diffuse fuel, such as dust, gas, or the vapors of an ignitable liquid, without the production of damaging pressure. Industrial flash fires result from the accidental release and ignition of flammable fuels. The size and duration of the flame that results from this ignition is determined by the amount of fuel available, the release conditions, the efficiency of combustion, and the environmental and physical characteristics of the site of the flash fire. The temperatures attained by flash fires have been estimated to range from 1000 to 1900 F (538 to 1038 C), but may be higher. Even the lowest estimated temperature is capable of causing most regular clothing fabrics to burst into flames. The primary harmful effects from a flash fire are the result of radiation and direct flame contact. Although flash fires can cause severe burns to unprotected workers, the literature provides little information on flash fires, probably because these hazards are considered less significant than blast effects that have occurred from the accidental release of flammable materials. Two reference documents were used to develop the BASF Flash Fire Assessment Tool. These included: (1) NFPA 2113, 2007 Edition Standard on Selection, Care, Use, and Maintenance of Flame-Resistant Garments for Protection of Industrial Personnel Against Flash Fire and (2) the Chemical Manufacturers Association (CMA), 1996 Edition A Manager s Guide for Assessing Flame Resistant Clothing Use. Basic Principals of Flash Fires For a flash fire to occur, a flammable liquid or gas must be present in a sufficient quantity to form a vapor or mist with concentrations within its flammable limits and it is ignited. Dust flash fires have similar characteristics to those of flammable liquid and gas with respect to temperature, heat flux and total heat energy; however, dust typically requires higher ignition energy and an appropriate particle size to ignite. Also, dust settlement on surfaces can create additional hazards. Typical exposure energy values for industrial flash fires are as follows: Heat Flux: 1-4 Cal/Cm2-Sec Exposure Times: 1-6 Sec Exposure Energies: 1-20 Cal/Cm2 Heat flux is the flow rate of energy onto a surface. Exposure energy = (Heat Flux) x (Exposure Time). As reference, 1 Cal/Cm2 is equivalent to the energy produced by a cigarette lighter in one second. An exposure of 1-2 Cal/Cm2 can cause a 2nd degree burn on human skin.

2 Protection from Flash Fires If a flash fire occurs in the presence of a worker, the predominant factors contributing to the severity of any burn sustained is the clothing being worn at that time, the intensity of the fire, and the duration of exposure. Protection from flash fires can be provided by wearing lightweight, flame resistant clothing. Worn on the outermost layer, FRC reduces the severity of burn injuries and increases the likelihood of survival in the event of a flash fire. This type of FR clothing is intended to protect workers from exposure to intense heat and flame for short periods of time. An altogether different type of protective clothing is required for situations where exposure to intense heat is frequent, normal, and of extended duration. FR clothing is unique because when exposed to high heat and flame for a short period, it does not burn, it does not melt, and it shields the clothing worn beneath it from the intense heat of the flame. FR fabrics are either inherently flame resistant (the fibers are of a material that itself does not burn), or are made of materials that undergo some type of treatment so that they are made non-flammable. Most of the clothing fabrics traditionally used for normal outerwear are inappropriate for use around flash fire hazards. Untreated cotton, polyester, nylon, and poly cotton blends are such examples. Untreated cotton has a very low ignition temperature of approximately 250 C and burns intensely and rapidly. Untreated polyesters and nylons ignite easily and melt readily. Nylon is also particularly prone to static build-up and is a recognized ignition source. Poly cotton blends combine the worst characteristics of both polyester and cotton. Clothing worn beneath FR clothing and against the skin should be made of FR fabrics or natural fibers that do not melt. Appropriate natural fibers include wool, silk, and cotton. Flash Fire Risk Assessment The tool presented in this document does not address evaluation of the need for FRC protection related to electrical arc flash, firefighting activities, chemical skin exposures, contact with hot surfaces, or blast wave effects. Use the instructions included in the tool to complete the assessment to determine the need for FRC in general work areas or for specific job tasks that pose a flash fire risk. Instructions The Flash Fire Assessment Tool is a 5-Step process that includes: (1) Material Hazards Screening; (2) Process Area Evaluation; (3) Job Task Evaluation; (4) Personnel Protection Assignments; and (5) Management Approval of the Assessment.

3 STEP 1. - To begin the FRC assessment, divide the unit being assessed into as many areas as necessary to facilitate identification of flash fire risks; based on equipment layout, job task assignments, building sections or floors. List materials used or produced in the process being evaluated, complete the material properties section, and answer the hazard threshold questions to determine if additional assessment steps are required. If the answer to a question in Steps 1(a) - 1(c) in the Hazard Threshold section is YES, continue with the evaluation of the respective Material(s) of Concern by proceeding to Step 2. If responses are NO for a listed material, further evaluation of that particular material is not required as the Flash Fire Hazard is considered to be minimal. The NPFA 704 (flammable) for Ratings are defined as follows: 0 = Materials that will not burn. 1 = Materials that require considerable preheating before ignition can occur. occur. Liquids with a flash point (f.p.) F. Solids in coarse dusts or fibrous forms that burn rapidly. Solids that readily give off flammable vapors. 3 = Liquids with f.p. < 73 F; B.P. > 100 F or f.p. > 73 F; B.P. < 100 F 4 = Flammable gases and cryogenic materials; Liquid or gaseous material with f.p. < 73 F; B.P. < 100 F. Note: When addressing the minimum ignition energy (MIE) for dusts, enter data for particulate materials including those that will be processed as solids and where combustible dusts may be generated. Typically, data will not be required for particulate materials received that are added to a process and dissolved or dispersed in a liquid, and that do not generate dust during this activity. Note: When completing material information for particle size, enter data for particulate materials, including those that will be processed as solids and where combustible dusts may be generated. Typically, data will not be required for particulate materials received that are added to a process and dissolved or dispersed in a liquid, and that do not generate dust during this activity. STEP 2. - Copy the Material(s) of Concern from Step 1 having a Yes response to any question in 1(a) - 1(c) into the left column, then address the Step 2 questions in Columns 1-6 for each Material of Concern to determine the potential need for FRC protection based on hazards in the process area being evaluated. Note: For Column 1, flash fire hazards may exist in work areas where flammable materials are handled, processed, stored, or in any way present. The most common definition of flash fire is a fire that spreads rapidly through a diffuse fuel, such as dust, gas, or the vapors of an ignitable liquid, without the production of damaging pressure. The duration of a flash fire is typically less than 6 seconds. If a fire has occurred, but it is unknown as to whether an initial flash occurred that could have injured personnel, include those situations here. Consider known history of the existing process at your site. If performing an initial assessment for a new process, research other locations using similar technologies and make an entry as appropriate.

4 Note: As guidance for Column 4, consider any area where vapors or gases are at a concentration to trigger any measurable level of LEL. Examples of combustible dust environments include operations where charging equipment is used with dusty materials, equipment for particulate grinding and blending, locations where dust is present on equipment or structural members, and areas where filter bags in dust collectors are changed. For each material of concern listed in Step 2, enter whether FRC "May be Required" or not in the final column under FRC Area Evaluation Results. STEP 3. - Copy the Material(s) of Concern from Step 1, having a Yes response to any question in 1(a) - 1(c), then list job tasks related to each Material of Concern that have the potential for release from process or storage equipment. Note: For Column 1, list task scenarios related to the Material of Concern. In particular, concentrate on tasks that may cause the release of these materials. In addition, list task scenarios where personnal working in the area have the potential for direct exposure to the Material of Concern. Examples include addition of chemicals to open processes, collection of process samples, clearing equipment such as pumps or lines, responding to small process leaks, venting lines, standard work tasks and accidental releases due to lifting in/over process areas, mobile equipment accidents in process areas, wrong line broken/opened, etc. Consider credible emergency release scenarios that may occur during the task as a result of a single fault. Note: Examples for Column 2 include: Draining chemicals to open containers or drainage area; purging gases to atmosphere; opening a normally contained vessel to add or remove components, etc. Note: Examples for Column 3 include: * Other potential workers in area that could be affected if a flash fire occurred from your task or that may be performing tasks that could contribute to a flash fire near your task. Consider accidental and normal release scenarios to determine reaches of that release. * Spilled barrel/drum; * Breaking a bleed off line while using rig to make a lift; * Flash from vat while uncovered; * Flammables spraying from a flange; *Etc. Note: Examples for Column 4 include: * Chipping tools; * Electrical tools; * Motors; * Vehicles; * Welding; * Hammer wrenches; * Etc. Note: Examples for Column 5 include: * Electrical motors; * Unrated electrical switches; * "Open" flames; * Stationary motors; *Etc.

5 For each material of concern listed in Step 3, enter whether FRC "May be Required" or not in the final column under FRC Task Evaluation Results. STEP 4. - List the Step 2 (Areas) or Step 3 (Job Tasks) that prompt a recommendation for FRC protection. Indicate if the FRC will be used as a general work uniform or donned prior to performing specific job tasks. In cases where a FRC "May be Required" rating was noted, but FRC is not used, list the engineering and administrative controls that will provide equivalent personnel protection from flash fire risks. STEP 5. - Obtain approval for the FRC assessment from the site/unit manager.

6 BASF Flame Resistant Clothing Assessment For Protection Against Flash Fire SITE: UNIT or DEPARTMENT: DATE OF ASSESSMENT: AREA or EQUIPMENT LOCATION BEING ASSESSED: STEP 1: Material Hazards Screening Worksheet List materials used or produced in the process being evaluated, complete the material properties section, and answer the hazard threshold questions. (If the answer to a question in Steps 1(a) - 1(c) is YES, continue with the evaluation of the respective Material(s) of Concern by proceeding to Step 2. If responses are NO for a listed material, further evaluation of that particular material is not required as the Flash Fire Hazard is considered to be minimal.) Material Properties Material Hazard Thresholds List Liquids, Gases and Dusts Present in the Process Physical State (Ambient Conditions) NFPA 704 Rating (Flammable) Flash Point ( F) Auto Ignition Temp ( F) Temp Material is Being Handled ( F) Minimum Ignition Energy (MIE for Dust in mj) Particle Size (For Dust in microns) 1(a) - Is NFPA 704 Flammable Rating = 4? 1(b) - Is a liquid being handled or processed above its flash point? 1(c) - Is combustible dust present where size < 75u; MIE < 100 mj; and moisture content < 10%?

7 BASF Flame Resistant Clothing Assessment For Protection Against Flash Fire SITE: AREA or EQUIPMENT LOCATION BEING ASSESSED: STEP 2: Process Area Evaluation Copy the Material(s) of Concern from Step 1 having a Yes response to any question in 1(a) - 1(c) into the left column below, then address the Step 2 questions in Columns 1-6 for each Material of Concern Evaluation of the Area's Flash Fire History Presence of Vapors, Gases, or Dusts Potential Ignition Sources Presence of Personnel Column 1 Column 2 Column 3 Column 4 Column 5 Column 6 Area FRC Evaluation Results (Enter "May Be Required" or "Not Required", as appropriate, for each row below.) List Process Materials of Concern From Step 1, having a Yes response to any question in 1(a) - 1 (c) Has a Fire ever occurred in the area that involved this material? Have any mechanical integrity incidents or other release incidents occurred in the area with this material that could have resulted in a Flash Fire? If a response in Columns 1 or 2 is YES, are there any corrective actions that were not implemented, completed, evaluated or demonstrated as effective in minimizing the potential for flash fire? (Attach a separate explanation of what happened and a description of the corrective actions.) Are flammable vapors, gases, or combustible dust from this material present in the work area atmosphere during normal operations? Are ignition sources present in the process or storage areas that could ignite materials addressed in Column 4? Is there potential for personnel to be near a source of flash fire that may occur with this material in the area? FRC may be required for the Area, based on the hazard assessment for the respective listed chemical(s), under the following conditions: A YES response is entered in Column 3; or A YES response is entered in each Column 4, 5, and 6

8 BASF Flame Resistant Clothing Assessment For Protection Against Flash Fire SITE: AREA or EQUIPMENT LOCATION BEING ASSESSED: STEP 3: Job Task Exposure Evaluation Copy the Material(s) of Concern from Step 1, having a Yes response to any question in 1(a) - 1(c), then list tasks related to each Material of Concern that have the potential for release from process or storage equipment. Column 1 Exposure Potential Ignition Potential FRC Task Evaluation Results (Enter May Be Required or Not Required, as appropriate, for each Column 2 Column 3 Column 4 Column 5 row.) List Process Materials of Concern From Step 1, having a Yes response to any question in 1(a) - 1 (c) Describe "Reasonably Anticipated Credible Release Scenarios" Related To Job Tasks Being Performed Does the task involve the potential for direct exposure to the material; i.e., handling or manipulation of the material? Is the task performed near other activities that have the potential to cause a flash fire that could affect personnel in the subject area? Does the task introduce a source of ignition for the material of concern? Are other ignition sources in the vicinity of the task that could ignite the material of concern? FRC may be required for respective job tasks under the following conditions: A YES response is entered in Columns 2 or 3; and A YES response is entered in Columns 4 or 5

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10 BASF Flame Resistant Clothing Assessment For Protection Against Flash SITE: AREA or EQUIPMENT LOCATION BEING ASSESSED: STEP 4: Risk Reduction and Personnel Protection List the Area or Job Tasks that May Require FRC Use. If FRC is Used, Indicate Plans to Don Before Use or Assign Uniform. If FRC is not Used, Describe the Alternative Protective Measures. Column 1 Column 2 If FRC is Necessary, Indicate How It Will i General Work Uniform List the Step 2 (Area) or Step 3 (Job Tasks) That Prompted A "FRC May Be Required" Determination If FRC is Not Used for the Area or Required for Routine Job Tasks Listed in Column 1, Enter Personnel in the Area (In the Rationale for Alternatives to FRC. Addition, Determine Requirements for Non-Routine Entrants; e.g., contractors, support staff, visitors) When Frequent Donning/Doffing Occurs for Tasks or Task Performance Cannot Be Predicted

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12 Fire n FRC as a General Work it be Used Task Protection Donned Prior to Performing Job Tasks Affected by the Material of Concern

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14 List the Members of the FRC Assessment Team Site/Unit Manager Approval I have reviewed the flame-resistant clothing (FRC) evaluation for the subject area and job tasks. I agree with the recommendations in this assessment regarding FRC requirements. Site/Unit Manager Name: Date: