NEBOSH DIPLOMA LEVEL 6

STORAGE & HANDLING OF DANGEROUS

SUBSTANCES
UNIT C4

REVISION
1.
2.
3.
4.

What is meant by Exothermic.

What is meant by Endothermic
What is the FP of a flammable liquid
Name three measures which can be
introduced to the design of a system
aimed at controlling pressure.

REVISION
1.
2.
3.

4.

What is meant by Exothermic. reaction gives

out heat energy
What is meant by Endothermic. reaction
absorbs heat energy.
What is the Flash Point of a flammable liquid . lowest temperature at which a flame will
propagate through the vapour of a combustible
material to the liquid surface.
Name three measures which can be introduced
to the design of a system aimed at controlling
pressure.- Pressure detectors & alarms.
Bursting discs, relief valves. Suppressant to
stop reaction.
3

CONTENT
STORAGE & HANDLING OF
DANGEROUS SUBSTANCES
Storage of
Dangerous Substances

REGULATIONS
DANGEROUS SUBSTANCE?
Dangerous Substances & Explosive
Atmosphere Reg 02 (DSEAR) define them as:a.
Substance or preparation which
is:Explosive.
Oxidising.
Extremely flammable.
Highly flammable.
Flammable.

REGULATIONS
DANGEROUS SUBSTANCE?
Dangerous Substances & Explosive
Atmosphere Reg 02 (DSEAR) define them as:Substance or preparation which because of its
chemical properties, the way it is used or
presence in the work place creates a risk of

explosion or fire.

REGULATIONS
DANGEROUS SUBSTANCE?
Dangerous Substances & Explosive
Atmosphere Reg 02 (DSEAR) define them as:c.
Any dust, either particle or
fibrous or otherwise which can
form an explosive mixture with air
or an explosive atmosphere.

REGULATIONS
DANGEROUS SUBSTANCE?
Dangerous Substances & Explosive
Atmosphere Reg 02 (DSEAR) defines an
explosive atmosphere as:one which has an accumulation of
either gas, mist, dust or vapour in air
which if mixed, could catch fire or
explode.

COMAH 1999
DANGEROUS SUBSTANCE?
Control of Major Accident Hazard 99
(COMAH) define them as:A substance, mixture or preparation listed
in Column 1 of Part 2 of Schedule 1 or
within category specified in Column 1 of
Part 3 of Schedule 1.

COMAH 1999
CLASSIFICATION
Very Toxic
Toxic
Oxidizing
Explosive
Flammable
FP 21oC 55oC
Highly Flammable
FP below 21oC
Extremely Flammable
FP below 0oC
Dangerous to the Environment

EXPLOSIVE
HAZARDOUS ATMOSPHERE
Classified within schedule 2 of COMAH 99 in
to three zones:Zone 0

Explosive atmosphere is present or

expected to be present.

Zone 1

Explosive atmosphere is likely to

occur.

Zone 2

Explosive atmosphere is unlikely to

occur.

Zone 1

Zone 0

Zone 2

12

EXPLOSIVE
HAZARDOUS ATMOSPHERE
Classified within schedule 2 of COMAH 99 in
to three zones in relation to dust :Zone 20

Explosive atmosphere is present or

expected to be present.

Zone 21

Explosive atmosphere is likely to

occur.

Zone 22

Explosive atmosphere is unlikely to

occur.

RISK ASSESSMENT
VARIOUS
The extent and detail of the assessment
should be relative to the complexity of the
hazard and the severity of the possible
consequences. Should include safety, health
and environment.
General Risk Assessment
COSHH Risk Assessment
HAZOP
Fault Tree Analysis
Failure Mode & Effect Analysis

Questions
As far as the risk of explosion or fire is
concerned, provide an accepted definition
of the term dangerous substance under
DSEAR.
List the physico-chemical properties that
make a substance dangerous
Describe the conditions that are defined as
Zone 0, Zone 1 and Zone 2 under DSEAR.
15

Group Exercise
In groups, research and summarise the
contribution of systems failures and
mechanical failures in the following major
accidents. From Element C2 and C4 in
RMS Study Book:
Flixborough
Abbeystead
Piper Alpha
Hickson & Welch
Grangemouth
Allied Colloids
Buncefield

16

Group Work
From the conclusions of the previous
group work on Major Accidents, try to
allocate the failure modes to the following
list:

17

FAILURE MODES
Site Design Fault
External Event
Fire/Explosion
Human Error
Impact
Container Failure
Maintenance Failure
Subsidence (shifting)

Impurities
Overheating
Overpressure
Overfilling
Structural Failure
Incorrect Procedure
Vibration

STORAGE

20

STORAGE
METHODS
The method of storage and the supporting
arrangements required to safely store a
dangerous substance depends on:a.
b.
c.

The nature of the substance

The quantity
The ambient conditions

STORAGE
TYPES
Bulk Storage Tanks
Intermediate tanks & Cylinders
Drums
Individual packaging
External

Tanks and compounds

Internal

Store Rooms, Compartment

BULK STORAGE

23

CONTROLS

(Preventative)

BULK STORAGE
Facilities & process design, meters & vents
Automatic alarms and fail safe systems
Flood, wind & lightning protection
Protect against static electricity
Fire/heat detection, alarm and action
Training, supervision, notices, permits to work
Good lighting, crash barriers, traffic control
Inspections, security, standard procedures
Structural & alteration inspection/checks

CONTROLS

(Mitigating)

BULK STORAGE
Automatic active fire precautions
Emergency response plans
Evacuation and Close Down procedure
Emergency trained staff
Pollution control, emergency space
Secondary containment, bunding
Segregation
PPE

External Storage
BUNDING
Bunded area able to hold 110% of largest
tank.
Intermediate walls to reduce surface area
Height of outer wall 1.5 m 2 m
Height of intermediate walls 0.5m
Construction material impervious
Rain water disposal
Drains protected
Prevention of weeds. (Dont use sodium
chlorate!!)

INTERMEDIATE BULK CONTAINERS

28

29

30

FAILURE MODES
DRUM, IBC & LPG Storage
Poor Work Systems
Container Failure
External Event
Impact
Maintenance Failure

Site Design Fault

Fire/Explosion
Overheating
Human Error

Question

Describe, with examples, three failure modes

that may result in spills and loss of contents from
drums, IBCs and LPG containers.
Group 1: Poor Work Systems, Site Design Fault,
Container Failure
Group 2: Fire/Explosion, External Event,
Overheating
Group 3: Impact, Human Error, Maintenance
Failure.
For the examples you have identified, suggest
control measures that may be introduced to
reduce the risk of accidents.
32

CONTROLS

(Preventative)

INTERMEDIATE, DRUMS & GAS

CYLINDERS
Stored outside, 2m fenced, secure compound
Flood, wind and lightning protection
Passive fire precautions
Training, supervision, notices, permits
Lighting, crash barriers, traffic control
Inspections, tests, security
In load and out load procedures
Segregation
Stacking, signage

CONTROLS

(Mitigating)

INTERMEDIATE, DRUMS and GAS

CYLINDERS
Impervious hard standing
Active fire precautions or cooling (Deluge)
Emergency response plans
Emergency trained staff
Spillage control & bunding
Minimal holding
Segregation

Deluge System

35

STORAGE
SEPARATION

(LPG Cylinders)

Distance from boundary and any risk of

ignition 50 kg = 1m : 5000 kg = 9 m.
Distance from top of fence to cylinders not
less than 1.5 m.
Low concentrations present hazard
Heavier than air and travels quickly
Odourless, difficult to detect

37

CONTROLS
DRUMS
No drum stored within 2m of any door, plain
glazed window or emergency exit.
Stored upright no more than 4 high.
If stored on side they should be chocked.
Drum handling equipment, not rolled.
Subject to inspection.
Used only for the substance designed for.
Spillage control & bunding.
Minimal holding.

INTERNAL STORAGE

FLAMMABLE SOLIDS
CONTROLS
Held in suitable storage, dry & ventilated
Quantities kept to a minimum.
Retained in correct packaging.
Clear & correct labelling.
Segregation related to hazard.
Subject to inventory control.
Subject to regular inspections.

FLAMMABLE LIQUIDS
CONTROLS
Separate store with 4 hrs fire protection.
Suitably located, fire routes and other hazards.
At ground level.
Bunded to prevent liquid escape.
All ignition sources eliminated.
Vented to the open air.
Store and containers mark.
Combustibles in area removed.
50lt max in workplace in suitable container

STORAGE
ROOMS OR BUILDING
Stores are for storing not work practices
Fit with non hazardous heating
Electrical equipment fit for zone
Ventilated, dry and free of rubbish
Well marked and signed
Fire protection, detection & fighting
Access controlled
Suitable storage and walkways
Emergency procedures in place

NOTIFICATION
QUANTITIES
Each dangerous substance has a limit on
quantity prior to notification to the authorities.
Dangerous Substances (Notification &
Marking of Site) Regs 90.
Planning (Hazardous Substances) Regs
92
Control of Major Accidents Hazards
Regs 99
Fire Certificate (Special Premises)
Regs 76

NOTIFICATION
QUANTITIES
25 tonnes or more of a Dangerous
site is subject to:-

Substance on any

Dangerous Substances (Notification & Marking

Regulation 90.

of Site)

This requires notification to the fire authority

and the
enforcing agency
Display warning and information signs at all points of entry

NOTIFICATION
QUANTITIES
60 gallons or more of a petroleum mix that gives of
vapours at a temperature less than
23oC is
subject to:Petroleum Consolidation Act 28
This requires a licence to be held which issued
the local authority

by

TOXIC & CORROSIVE

DESCRIPTIONS
Toxic
them.

Dangerous to the living things

around

Corrosive
Include acids acid anhydrides
and
alkalis. They can be volatile
and create toxic or
explosive
fumes. They can destroy living
tissue and structural materials

TOXIC & CORROSIVE

SAFETY PRINCIPLES
Use the safest practicable substance.
Retain minimum amount in appropriate
bringing in to use the minimum amount.

storage

Segregate substance which react with

other.

each

Acid
Inorganic

Acid
Oxidizing

Acid
Organic

Alkali

Acids,
Inorganic

Acid
Oxidizing

Acid
Organic

Alkali

Oxidizers

Poison
inorganic

Poison
organic

Water
re active

Organic
solvents

Oxidizers

Poison
inorganic

Poison
organic

Water
re active

Organic
solvents

TOXIC & CORROSIVE

STORAGE SEPARATION
Examples of separation in storage:Carbon Tetrachloride exposed to high
temperatures will form highly toxic phosgene
gas
Acid reacts to cyanides, sulphides, fluorides,
carbides, phosphides to produce toxic fumes
Alkaloids react to release hydrogen on
contact with aluminium

GROUP WORK 6 - 1
In your groups design a
suitable storage facility
for:60 tonnes of toxic
chemical held in 6 10
tonne tanks
4,000 Lt of toxic liquid
held in 200Lt steel
drums
1,000 Lt of corrosive
chemical held in 1Lt
glass bottles

NEBOSH DIPLOMA LEVEL 6

HANDLING & USE

OF DANGEROUS SUBSTANCES
UNIT C4

CONTENT
STORAGE & HANDLING OF
DANGEROUS SUBSTANCES
Handling and Use
of Dangerous Substances

REGULATION
USE & HANDLING
Both of these functions are regulated by COSHH
2002, together with other relevant legislation.
Additional regulations govern the storage and
transportation of specified dangerous
substances in given quantities.

54

PIPELINES
CONTROLS Remember Flixborough!
The accident was traced to a poorly qualified design team that was asked to design
and install temporary piping in a Cyclohexane Oxidation Unit. That temporary piping
catastrophically failed, releasing 50 tonnes of hot, pressurized cyclohexane.

Correct design for content & stresses

Suitable construction, valves & gauges
Maintenance of correct pressure & flow
Static electricity managed
Emergency planning & response
Maintenance & inspections - corrosion & fractures,
Security: Pipelines Safety Regulations 96
55

FILLING CONTAINERS
CONTROLS
Assess the risk
Check contents or past contents
If required clean container
Eliminate sources of ignition
Trained and supervised staff
Put earthing/bounding in place
Display warning signs.
Persons involved to the minimum
PPE & Fire precautions with First Aid

56

EXPLOSIVE LEVELS
Lower Explosive
Level (LEL)
Flammable Range

Too Little

Upper Explosive
Level ( UEL)

Too
Much
Maximum Explosive
Pressure

Vapour/Gas Concentration in Atmosphere

57

DISPENSING
PETROLEUM (CONSOLIDATION)
ACT 28
Premises which dispense petrol into vehicles,
ships, boats or planes require a licence to do
so under the above.
Premises which store petrol for other
purposes do not, but they must comply with
DSEAR 02, or if quantities dictate COMAH
99 plus other relevant regulations
58

DISPENSING
FLAMMABLE LIQUIDS
Vapours pose a risk of fire/explosion
Confined spaces will create concentration
Vapours are heavier than air, settle and spread
Low ground, pits and sumps
Liquid floats on water, distance travelled
IND(G) 227 Safe working with flammable substances

59

SPRAYING
FLAMMABLE LIQUIDS
Controls
Assess the risk
Control vapours by ventilation/extraction
Maintain below the lower explosive limit
Eliminate all sources of ignition
Spray booths are Zone I areas
Earth equipment, anti static measures
60

ELECTRICITY
FLAMMABLE LIQUIDS
Movement can produce static
Plant may produce spark
Intrinsically electrical safe plant
Well maintained and inspected planted
Earthing & Bonding
Switched off and locked
Safe distance
Safe tools and lighting
61

FLAMMABLE SUBSTANCES
SAFETY PRINCIPLES
Ventilation: Avoids fume concentration
Ignition:

Remove all sources

Containment: Suitable containers/bunds

Exchange: Reduce the risk by substitution
Separation: Physical barrier or distance
IND(G) 227 Safe working with flammable
substances

62

ASSESSMENT
Stage 2

Stage 1

Identify maximum
Obtain details on all
holdings and location of
hazardous substances
substances. Assess
from supplier and other
safeguards in place
sources
Stage 3
Provide additional measures if needed to meet legal
standards. Consult with authorities and check if licensing or
certificates are needed.
Stage 4
Monitor to ensure substances and quantities remain
unchanged and standards are maintained

HOMEWORK 4
Outline the safety
provisions required for
the design, operation and
maintenance of a water
treatment plant which
must store in bulk large
quantities sulphuric acid
and caustic soda. Both
substances are delivered
by road tankers