DOE-HDBK-1139-2005 Volume 3, Chemical Management Volume 3: Consolidated Chemical User Safety and Health Requirements

TS NOT MEASUREMENT SENSITIVE DOE-HDBK-1139/3-2005 April 2005 DOE HANDBOOK CHEMICAL MANAGEMENT (Volume 3 of 3) Consolidated Chemical User Safety and Health Requirements U.S. Department of Energy AREA SAFT Washington, D.C. 20585 DISTRIBUTION STATEMENT A. Approved for public release; distribution is unlimited. DOE-HDBK-1139/3-2005 i This document has been reproduced directly from the best available copy. It is available to DOE and DOE contractors from ES&H Technical Information Services, U.S. Department of Energy, (800) 473-4375, fax: (301) 903-9823. It is available to the public from the U.S. Department of Commerce, Technology Administration, National Technical Information Service, Springfield, VA 22161; (703) 605-6000. DOE-HDBK-1139/3-2005 ii Foreword Numerous requirements have been promulgated to protect workers, equipment, facilities and the environment. When work is performed, the specific requirements affecting the work must first be identified and incorporated into the work-plan. Because such requirements can number in the thousands, simply identifying all of the applicable chemical safety-related safety and health requirements that govern any work activity can be a monumental task. Concern over this was addressed in the 1994 DOE Chemical Vulnerability Study Management Response Plan, which identified the need for a complex-wide "Roadmap for Requirements". Similarly, discussions within the Energy Facility Contractors Group (EFCOG)/DOE chemical safety community have indicated that one of the main causes of continuing chemical safety deficiencies at DOE is the large number of requirements that govern chemical-related work at the Complex. Many of these requirements approach chemical safety from different perspectives and contain provisions that overlap and are sometimes contradictory and confusing. An EFCOG/DOE Chemical Safety Topical Committee (CSTC) Team, the Chemical User Safety and Health Requirements Roadmap (CUSHR) Team, undertook the task of looking into this issue. Background The EFCOG/DOE CSTC CUSHR Team conducted a limited review of how DOE sites address compressed gases. Results showed that at these sites, only 50-70% of requirements were addressed in site documentation of chemical-related safety and health requirements. These results confirmed the view that while all DOE contractors who engage in the same work activities must follow the same requirements, many either do not know which requirements apply to their work or are confused by them. The Team concluded that this was likely due to the fact that multiple requirements from many varied sources frequently overlap, covering the same points in slightly different and sometimes conflicting ways. To assist the sites in understanding and addressing the myriad requirements with which they must comply, the CUSHR Team committed to developing a series of activity-based chapters that consolidate the safety and health requirements that govern DOE chemical-related work activities, removing overlaps and duplications, where found. Before beginning its work, the Team conducted a Chemical Storage Requirements Pilot in the summer of 2000 to see if this planned effort would be perceived as "value-added" for the DOE community. The pilot document provided consolidated chemical-related safety and health requirements for chemical storage, a universal activity conducted by all that use chemicals throughout the Complex. A listing of consolidated requirements for safe chemical storage, along with a survey was distributed to chemical users across the Complex. The survey results demonstrated that the effort to consolidate requirements will be useful to chemical users throughout the Complex and should continue.

In support of this mandate to assist the sites with a requirements roadmap, the CSTC CUSHR Team developed a series of activity-based chapters which consolidate the safety and health requirements that govern DOE chemical-related work activities. The ten chapters of this document, Volume 3 of the DOE Chemical Management Handbook, coordinate with the subjects covered in that Handbook. Instructions for Use This volume consolidates existing core safety and health requirements that all sites engaged in chemical- related activities must follow when applicable and when no exemptions have been granted. It is intended to consolidate overlapping and/or duplicative chemical-related safety and health requirements. It serves DOE-HDBK-1139/3-2005 iii only to consolidate existing DOE and Federal chemical-related safety and health requirements. It does NOT create any new or additional requirements. The listing of consolidated requirements contained here includes “pointers” to the sources of those requirements, showing the user what the requirements are and where each comes from. In addition to DOE Orders, it includes Occupational Safety and Health Administration (OSHA), National Fire Protection Association (NFPA), American National Standards Institute (ANSI), and Compressed Gas Association (CGA) requirements that are cited in either DOE O 440.1A or in OSHA standard 29CFR1910.6 ("Incorporation by Reference"). It also includes technical standards that are made mandatory by their specific reference within a regulation, rule or DOE Order. State and local codes including locally adopted building and fire codes are NOT addressed in this document. U.S. Department of Agriculture (USDA) regulations are NOT addressed since the impact from these is considered to be negligible at DOE facilities. Similarly, U.S. Environmental Protection Agency (EPA) pesticide regulations are NOT addressed in this document. In the web-based version of this document, wherever possible, the referenced requirements are hyperlinked directly to their source documents. For each consolidation, a source document that is repeated is hyperlinked only once. Since ANSI, CGA, and NFPA documents are available only to subscribers to those organizations, the hyperlinks for those referenced requirements will take the reader only to the web pages of those organizations. Subscribers can then access the specific requirements of interest. Non-subscribers may be able to find these documents in their site libraries or can purchase them through the organizations' web pages. This Requirements Roadmap contains a Glossary of terms and explanatory notes of the various consolidated chemical-related safety and health requirements. The numerous requirements included in this document come from a large number of sources that have different safety purposes. As a result, some of these requirements may not always be applicable to the work being performed at an individual site or facility. It is the responsibility of each user to determine the applicability of these requirements to their work and how they are implemented. The reference sources for the requirements included in this document can be used to determine the applicability of those requirements to the work being performed. The source requirements are listed to the left of the corresponding section of the document that consolidates the referenced requirements. If there is any question as to the applicability of a requirement or if it is thought that any requirement is taken out of context, then the reader can use the reference sources to research the original requirement.

Due to changing regulatory requirements and revisions to consensus standards the user should contact the subject matter expert (e.g., Fire Protection Engineer, Industrial Safety Engineer, Industrial Hygienist, Environmental Engineer, etc.) to ensure that the most current document is used, as applicable, depending on site contractual requirements. DOE-HDBK-1139/3-2005 iv Table of Contents Foreword...................................................................................................................................................iii Acknowledgements...................................................................................................................................vi Glossary ....................................................................................................................................................vii Acronyms and Abbreviations ..................................................................................................................xxi Chapter 1 - Hazard Analysis .....................................................................................................................1 Chapter 2 - Acquisition.............................................................................................................................7 Chapter 3 - Chemical Inventory and Tracking..........................................................................................11 Chapter 4 - On-Site Chemical Transportation ..........................................................................................17 Chapter 5 - Chemical Storage ...................................................................................................................23 Chapter 6 - Hazard Control.......................................................................................................................39 Chapter 7 - Pollution Prevention and Waste Minimization ......................................................................67 Chapter 8 - Chemical Emergency Management .......................................................................................75 Chapter 9 - Chemical Disposition.............................................................................................................97 Chapter 10 - Training ...............................................................................................................................129 Complete List of Sources..........................................................................................................................141 Chapter Overviews ………………………………………………………………………………...........145 DOE-HDBK-1139/3-2005 v ACKNOWLEDGEMENTS This Department of Energy Handbook was prepared under the sponsorship of the joint Department of Energy (DOE)/Energy Facility Contractors Group (EFCOG) Chemical Safety Topical Committee (CSTC). It was prepared over a span of four years by the CSTC’s Chemical User Safety and Health Requirements Roadmap team (the CUSHR team), consisting of representatives from several sites and DOE headquarters, chaired by Dr. Dave Quigley, BWXT Y-12 and co-chaired by Mr. James Morgan, Westinghouse Savannah River Company and Ms. Gail Kleiner, DOE/EH-52. The preparers would like to gratefully acknowledge the following specific CUSHR team members who authored the various chapters of this document: Judi Johannesen, PNNL Fred Simmons, WSRC Murty Kuntamukkula, WSRC Bill Westendorf, Link Technologies, Inc. John Piatt, PNNL James Woodring, ANL Dave Quigley, INEEL Jeff Woody, Link Technologies, Inc.

No one group of individuals, however, can appropriately take sole credit or responsibility for an undertaking of this magnitude. The CSTC CUSHR Team would like to gratefully acknowledge the large number of individuals who have provided comments on the handbook. Beyond the formal comment process used for documents of this type, the following individuals provided valuable technical insights and/or specific reviews of this document in its various stages of development: Theresa Aldridge DOE-RL Ann Schubert WVNS Ed Branagan DOE-HQ/NE John Serocki DOE-HQ/NE-70 Jerry Coalgate DOE-HQ/EH-413 Reanna Sharp-Geiger LANL Arnold Edelman DOE-HQ/SC-83 Daniel Stachelski DOE-WV David Freshwater SAIC Tom Tuccinardi DOE-HQ/SO-411 Brenda Hawks DOE-ORO J. C. Laul LANL Rob Vrooman NNSA/NA-53 Bill McArthur DOE-HQ/EH-52 Sharon Walker SNL James T. Powers NNSA/NA-41 Steven Woodbury DOE-HQ/EH-43 Jane Powers DOE-HQ/EH-413 Stephanie Woolf DOE-ID DOE-HDBK-1139/3-2005 vi Glossary Abandon: leave in place. Approval: authorization from subject matter experts or the appropriate level of management as defined in local site or facility procedures; or Approved: acceptable to the authorities having jurisdiction. CERCLA Hazardous Substance: a substance on the list defined in section 101(14) of CERCLA. Certain Categories of Property (that Require Special Handling): specific types of hazardous property, the disposition of which is described in 41CFR109-42.11 and 41CFR101-42.1102, such as Radioactively or chemically contaminated property, Asbestos, Polychlorinated biphenyls (PCBs), Controlled substances, Nuclear Regulatory Commission (NRC)-controlled materials, Drugs and reagents other than controlled substances, Lead-containing paint, U.S. Munitions List (see definition) that require demilitarization (see definition), etc.. Chemical: any element, compound or mixture of elements and/or compounds. A substance that a) possesses potentially hazardous properties (including, but not limited to flammability, toxicity, corrosivity, reactivity); or b) is included on any federal, state, or local agency regulatory list; or c) is associated with an MSDS and is not an “Article” as defined in 29CFR1910.1200. For the purposes of this document this definition also applies to chemical product (see definition). Chemical Product: a mixture of any combination of two or more chemicals that may or may not be the result, in whole or in part, of a chemical reaction, and that itself has hazardous properties. Chemical products will have Material Safety Data Sheets (MSDS) associated with them and include materials such as paints, lubricants, cleaning agents, fuels, etc.. Chemical Storage Area: a location that is segregated by either physical barriers or a distance approved by a Fire Protection Engineer and is used to store any chemical except those that are classified as being low hazard (see definition). Example 1: If a flammable liquid storage cabinet is in a work area, then the inside of the cabinet is the storage area, not the entire work area. Example 2: Areas used to store chemicals that are of a low hazard are not considered to be chemical storage areas. Types of chemical storage areas include flammable liquid storage areas, oxidizer storage areas, and organic peroxide storage areas. Chemical Tracking: monitoring changes to the inventory data for chemicals over time from acquisition to disposition in order to keep the inventory up-to-date.

Class I Flammable Liquids: Class 1A, Class 1B, and Class 1C flammable liquids. Class IA Flammable Liquids: liquids having a flash point less than 73°F and boiling points below 100°F. Class IB Flammable Liquids: liquids having a flash point less than 73°F and boiling points at or above 100°F. DOE-HDBK-1139/3-2005 vii Class IC Flammable Liquids: liquids having a flash point at or above 73°F and below 100°F. Class II Combustible Liquids: liquids having a flash point greater than 100°F but less than or equal to 140°F. Class IIIA Combustible Liquids: liquids having a flash point greater than 140°F but less than or equal to 200°F. Class 1 Oxidizer: an oxidizer that will not result in spontaneous combustion when it comes into contact with combustible materials, but will slightly increase the burning rate of combustibles that have already been ignited. Class 2 Oxidizer: an oxidizer that may cause spontaneous ignition when it comes into contact with combustible materials or that will cause a moderate increase in the rate at which a combustible will burn. Class 3 Oxidizer: an oxidizer that will undergo a vigorous self-sustained decomposition when exposed to contamination or heat or that will cause a severe increase in the rate at which combustibles will burn. Class 4 Oxidizer: an oxidizer that will explosively decompose upon exposure to heat, shock or contaminants. Clean-Up Operations: an operation where hazardous substances are removed, contained, incinerated, neutralized, stabilized, cleared-up, or in any other manner processed or handled with the ultimate goal of making the site safer for people and the environment. Commerce Control List Items1: dual use (i.e., commercial/military) items that are subject to export control by the Bureau of Export Administration, Department of Commerce. These items have been identified in the U.S. Export Administration Regulations (15CFR774) as export controlled for reasons of national security, crime control, technology transfer and scarcity of materials. Commission: the emergency response commission for the State in which the facility is located or the Indian Tribe under whose jurisdiction the facility is located. In the absence of an Emergency Response Commission, the Governor and the chief executive officer, respectively, shall be the commission. Where there is a cooperative agreement between a State and a Tribe, the commission shall be the entity identified in the agreement. Committee or Local Emergency Planning Committee (LEPC): the local emergency planning committee appointed by the emergency response commission. 1 The Commerce Control List includes deuterium, heavy water, other compounds of deuterium; nuclear-grade graphite; chemical agents (e.g., tear gas formulation, smoke bombs, and other pyrotechnic articles) having dual military and commercial use; propellants and constituent chemicals (e.g., fine powders of high-purity aluminum, beryllium, iron, magnesium, zirconium, boron or boron carbide); guanidine nitrate; liquid oxidizers (e.g., dinitrogen trioxide, nitrogen dioxide/ dinitrogen tetroxide, dinitrogen pentoxide); certain alloys and polymer composites; high purity (99.99% or greater) bismuth; hafnium metal and alloys (>60%Hf); helium-3; chlorine trifluoride; precursors for toxic chemical agents, etc.. DOE-HDBK-1139/3-2005 viii

Confined Space: any space not intended for continuous human occupancy and having a limited means of egress. A permit-required confined space contains or has the potential for a hazardous atmosphere (toxic, flammable, or oxygen deficient) and/or engulfment or entrapment hazards. Confined or enclosed spaces include, but are not limited to, storage tanks, process vessels, bins, boilers, ventilation or exhaust ducts, sewers, underground utility vaults, tunnels, pipelines, and open top spaces more than 4 feet in depth such as pits, tubs, vaults, and vessels. Controlled Substances: a drug or other substance, or immediate precursor, included in Schedule I, II, III, IV or V of Part B of Title 21USCS Section 812. The term does not include spirits, wine, malt beverages or tobacco, as those terms are defined ot used in subtitle E of the Internal Revenue Code of 1954 [26 USCS Sections 5001, et seq.] Cryogenic Liquids: gases that are handled in liquid form at relatively low pressures and extremely low temperatures, usually below –130° F (-90º C). Dangerous Property: material that exists in a condition that poses a hazard to public health or safety and thus, requires special care and handling. Decontamination: the removal of hazardous substances from employees and their equipment to the extent necessary to preclude the occurrence of foreseeable adverse health effects. Demilitarization: as defined by the Department of Defense, the act of destroying the military capabilities inherent in certain types of equipment or material. Such destruction may include deep sea dumping, mutilation, cutting, crushing, scrapping, melting, burning, or alteration so as to prevent the further use of the item for its originally intended purpose. Disposal: the discharge, deposit, injection, dumping, spilling, leaking, or placing of any solid waste or hazardous waste into or on any land or water so that such solid waste or hazardous waste or any constituent thereof may enter the environment or be emitted into the air or discharged into any waters, including ground waters. Disposition: the process of reutilizing, transferring, donating, selling, abandoning, destroying, or other disposition of Federal government-owned personal property (i.e., chemicals and chemical products). DOE Screening Period: the period of time that reportable excess chemicals (see definition) are screened throughout the DOE complex for reutilization purposes. Donee: any of the eligible entities that receive Federal surplus personal property (i.e., chemicals) through a State Agency for Surplus Property (see definition), for example, a public agency (see definition), a nonprofit tax-exempt educational or public health institution, or a State or local government agency. Departmental Property Management Officer: also designated as the DOE National Utilization Officer who provides approval for user access to the Federal Disposal System (FEDS) (see definition). DOE-HDBK-1139/3-2005 ix Dual-use List2: a list of nuclear-related material, equipment, software, and related technology, that can have valid uses in both commercial and military applications, developed by the Nuclear Suppliers Group (see definition) and described in the International Atomic Energy Agency (IAEA) Information Circular (INFCIRC) 254 Part 2.

Energy Asset Disposal System: a module within the Federal Disposal System (FEDS) (see definition) database, available to DOE and DOE contractor personnel to conduct internal screening of excess chemicals for use within the agency; it became effective Sept. 1, 1998. [NOTE: EADS has replaced the Reportable Excess Automated Property System (REAPS) mentioned in 41CFR109-43.304-1.50]. Environmental Management System: The environmental policy, environmental performance, objectives and targets, implementing program to achieve those objectives, monitoring and measuring of program effectiveness, environmental problem correction, and continuous improvement process that helps a company manage, measure, and improve the environmental aspects of its operations. Environment: includes water, air, and land and the interrelationship that exists among and between water, air, and land and all living things. Especially Designed or Prepared Property: equipment and material designed or prepared especially for use in the nuclear fuel cycle and described in the Nuclear Suppliers Group (see definition) Trigger List (see definition) (INFCIRC 254 Part 1). Especially Designed or Prepared Property is a category under High Risk (Personal) Property (see definition). Excess Chemicals: Chemicals (see definition) or Chemical Products (see definition) that are still in good condition and for which the current owner has no further use. This does not include spent/used material. [NOTE: This term is used in DOE-PMR and FPMR to mean chemicals that are excess to a holding agency (see definition), such as DOE, that can only be reutilized within the same agency or by another federal agency]. It includes chemicals identified as high risk personal property, hazardous property, hazardous materials, extremely hazardous materials, hazardous items, and certain categories of property that require special handling (see definitions). Excess (Personal) Property: any personal property under the control of any Federal agency (the DOE, for purposes of this document) that is no longer required for that agency's needs, as determined by the agency head or designee. Excluded PCB products: materials containing 0 through 49 ppm (see definition) PCB (see definition). Export Controlled Property: property, the export of which, is subject to licensing by the U.S. Department of Commerce, the U.S. Department of State, the U.S. Nuclear Regulatory Commission, or is authorized by the U.S. Department of Energy. Export Controlled Property is 2 The Dual-use List includes several metals (e.g., beryllium, and zirconium) and their alloys, and certain high explosives. DOE-HDBK-1139/3-2005 x a category under High Risk (Personal) Property (see definition). Refer to the Commerce Control List (see definition) for items that are export controlled. Extremely Hazardous Materials: (a) those materials that are hazardous to the extent that they generally require special handling such as licensing and training of handlers, protective clothing, and special containers and storage; (b) those materials that, because of their extreme flammability, toxicity, corrosivity or other perilous qualities, could constitute an immediate danger or threat to life and property and that usually have specialized uses under controlled conditions; and (c) those materials that have been determined by the holding agency (see definition) to endanger public health or safety or the environment, if not rendered innocuous before release to other agencies or to the general public.

Extremely Hazardous Substance: a substance listed in appendices A and B of 40CFR355. Federal Disposal System: a real-time, online computer database managed by the GSA (since 1992) for recording, tracking and controlling the nationwide inventory of excess and surplus personal property inventory (e.g., equipment, commodities, including chemicals) of the Federal government. For additional information on using FEDS, access http://pub.fss.gsa.gov/property/. Fire Area: an area in a building that is separated from the rest of the building by a one- hour fire barrier. All penetrations through this fire barrier must be constructed to maintain the one-hour fire resistance. First Responder - Awareness Level: individuals who are likely to witness or discover a hazardous substance release and who have been trained to initiate an emergency response sequence by notifying the proper authorities of the release. They are temporarily in command of the incident until the Incident Commander (IC) arrives. They would take no further action beyond notifying the authorities of the release. First Responder - Operations Level: individuals who respond to releases or potential releases of hazardous substances as part of the initial response to the site for the purpose of protecting nearby persons, property, or the environment from the effects of the release. They are trained to respond in a defensive fashion without actually trying to stop the release. Their function is to contain the release from a safe distance, keep it from spreading, and prevent exposures. Flammable Liquids Storage Rooms: rooms that are designed according to 29CFR1910.106 (d)(4) for the storage of flammable and combustible liquids. Flammability Rating of “0” or “1”: liquids, solids or semi-solids that have a flash point above 200°F or those materials which will not burn when exposed to a temperature of 1500°F for 5 minutes. Friable Asbestos Materials: materials that contain more than one percent asbestos by weight and that can, by hand pressure, be crumbled, pulverized, or reduced to powder, thus allowing for potential release of asbestos fibers into the air. Foreseeable Emergency: any potential occurrence such as, but not limited to, equipment failure, rupture of containers, or failure of control equipment which could result in an uncontrolled release of a hazardous chemical into the workplace. DOE-HDBK-1139/3-2005 xi Hazard: potential for radiation, a chemical, biological agent or other pollutant that causes human illness or injury. Hazard Analysis: the determination of material, system, process, and plant characteristics that can produce undesirable consequences, followed by the assessment of hazardous situations associated with a process or activity. Largely qualitative techniques are used to pinpoint weaknesses in design or operation of the facility that could lead to accidents. Hazardous Chemical: any chemical (see definition) that presents a physical hazard or a health hazard. A substance that possesses potentially hazardous properties (including, but not limited to flammability, toxicity, corrosivity, reactivity). Hazard Control: the management actions or physical measures taken to eliminate, limit, or mitigate hazards to workers, the public, or the environment, including (1) physical, design, structural, and engineering features; (2) safety programs and procedures; (3) personal protective equipment; and (5) administrative limits or operational restrictions.

Hazardous Material: property that is deemed a hazardous material, chemical substance or mixture, or hazardous waste under the Hazardous Materials Transportation Act (HMTA), the Resource Conservation and Recovery Act (RCRA), or the Toxic Substances Control Act (TSCA).3 Generally, a hazardous material has one or more of the following characteristics: (a) has a flash point below 200°F (93.3°C), closed cup, or is subject to spontaneous heating; (b) is subject to polymerization with the release of large amounts of energy when handled, stored, or shipped without adequate controls; (c) in the course of normal operations, may produce fibers, dusts, gases, fumes, vapors, mists, or smokes which have one or more of the following characteristics: (1) causes 50 percent fatalities to test animals below 500 mg/kg of test animal weight when a single oral dose is used (LD50); (2) is a flammable solid or a strong oxidizing or reducing agent; (3) causes first degree burns to skin in a short time exposure, or is systemically toxic by skin contact; (4) has a permissible exposure limit (PEL) below 1000 ppm for gases and vapors, below 500 mg/mm3 for fumes, below 10 mg/m3 or 2 fibers/cm3 for dust; (5) causes occupational chemical dermatitis, which is any abnormality of the skin induced or aggravated by the work environment that includes, but is not limited to, primary irritant categories, allergic sensitizers, and photo sensitizers; (d) is radioactive to the extent that it requires special handling; (e) is a recognized carcinogen according to Occupational Safety and Health Administration (OSHA) regulations at 29CFR1910; or (f) possesses special characteristics, which in the opinion of the holding agency (see definition), could be hazardous to health, safety, or the environment if improperly handled, stored, transported, disposed of, or otherwise improperly used. Hazardous Materials Branch Officer: responsible for directing and coordinating all hazardous materials operations assigned by the incident commander. 3 Also see the National Oil and Hazardous Substances Pollution Contingency Plan, 40CFR302.4, for listing of Hazardous Substances. DOE-HDBK-1139/3-2005 xii Hazardous Materials Regulations: Department of Transportation (DOT) Title 49 Code of Federal Regulations (CFR) Parts 106-199. Hazardous Materials Specialists: individuals who respond with and provide support to hazardous materials technicians. Their duties parallel those of the hazardous materials technician; however, those duties require a more directed or specific knowledge of the various substances they may be called upon to contain. The hazardous materials specialist also serves as the site liaison with Federal, state, local and other government authorities as regards site activities. Hazardous Materials Technicians: individuals who respond to releases or potential releases for the purpose of stopping the release. They assume a more aggressive role than a first responder at the operations level in that they will approach the point of release in order to plug, patch or otherwise stop the release of a hazardous substance. Hazardous Operations: includes process operations that are subject to regulatory actions because of the presence of one or more specific hazardous materials or types of materials that meet or exceed established thresholds or guidelines. These include operations with chemicals governed by: • 29CFR1910.119, “Process Safety Management of Highly Hazardous Chemicals” or

40CFR68.67, “Chemical Accident Prevention Provisions-Process Hazards Analysis;” • hazard category 1, 2, or 3 nuclear operations as defined in 10CFR830, “Nuclear Safety Management;” • operations with Beryllium as defined by 10CFR850; • facilities with “significant” fire hazards as defined by DOE O 420.1A; • hazardous waste operations as defined in 29CFR1910.120, “Hazardous Waste Operations and Emergency Response;” and • activities subject to NEPA environmental assessment or environmental impact statements as defined in 10CFR1021.400. Hazardous (Personal) Property: any personal property, including scrap (see definition) or waste but excluding property involving a radiological hazard, that is ignitable, corrosive, reactive, or toxic because of its quantity, concentration, or physical, chemical, or infectious characteristics, or that is deemed a hazardous material, chemical substance or mixture, or hazardous waste under the Hazardous Material Transportation Act (HMTA) (49 U.S.C. 5101), the Resource Conservation and Recovery Act (RCRA) (42 U.S.C. 6901-6981), or the Toxic Substances Control Act (TSCA) (15 U.S.C. 2601-2609). Such property may be in solid, liquid, semi-liquid, or contained gas form and may cause or significantly contribute to an increase in mortality or illness, or pose present or potential hazard to human health or the environment when improperly used, treated, stored, transported, disposed of, or mismanaged. Hazardous (Personal) Property is a category under High Risk (Personal) Property (see definition). Hazardous Substance: for the purposes of this document, as defined in 29CFR1910.120: “…A) any substance defined under section 101(14) of CERCLA; B) any biologic agent and other disease causing agent which after release into the environment and upon exposure by ingestion, inhalation, or assimilation by any person, either directly from the environment or indirectly by ingestion through food chains, will or may reasonably be anticipated to cause death, disease, behavioral abnormalities, cancer, genetic mutation, physiological malfunctions (including malfunctions in reproduction) or physical deformations in such persons or their offspring; C) any DOE-HDBK-1139/3-2005 xiii substance listed by the U.S. Department of Transportation as hazardous materials under 49CFR172.101 and appendices; and D) hazardous waste either as a waste or combination of wastes as defined in 40CFR261.3, or those substances defined as hazardous wastes in 49CFR171.8.…”. Hazardous Waste4: those materials or substances, the handling and disposal of which are governed by 40CFR261, 29CFR1910.120, and 29CFR1926.65. High Risk (Personal) Property5: property that, because of its potential impact on public health and safety, the environment, national security interests, or proliferation concerns, must be controlled, and dispositioned in other than the routine manner. The categories of high risk property are (1) Especially designed or prepared property, (2) Export controlled property, (3) Proliferation-sensitive property, (4) Nuclear weapon components or weapon-like components, (5) Hazardous property, (6) Automatic data processing equipment, (7) Export controlled information, (8) Radioactive property, (9) Special nuclear material, and (10) Unclassified controlled nuclear information. Holding Agency: the Federal agency having accountability for, and generally possession of, the chemicals involved.

Incident Commander: assumes control of the incident scene. Inside Liquid Storage: a location inside a building that is segregated by either physical barriers or a distance approved by a Fire Protection Engineer and is used to store any liquid chemical except those that are classified as being low hazard (see definition); a room or building used for the storage of liquids in containers or portable tanks, separated from other types of occupancies. Inside room: a room totally enclosed within a building and having no exterior walls. Internal Screening Period: See DOE Screening Period (definition). Labeling: a descriptive name, identification number, instructions, cautions, etc. to be placed directly on the primary container of hazardous materials. 4 The definition for hazardous waste, as given in 41CFR101-42.001, includes the following caveats: (a) In general, hazardous materials (see definition) are hazardous wastes when one or both of the following is true: 1. they have passed through the disposition cycle without having been successfully reutilized, transferred, donated, or sold, and the holding agency declares an intent to discard them. 2. they are no longer usable for their intended purpose, a valid alternate purpose, or resource recovery. (b) In general, solid (non-hazardous) wastes, as defined at 40CFR261.2, become hazardous wastes when: 1. they exhibit one or more of the characteristics of ignitability, corrosivity, reactivity, or EP (Extraction Procedure) toxicity; or 2. they are predetermined hazardous wastes upon generation as listed in 40CFR261, Subpart D. 5 Excess chemicals identified as high risk personal property are most likely to belong to category (5), (2) or (3). DOE-HDBK-1139/3-2005 xiv Laboratory units: for a complete overview of laboratory units and their definition, see NFPA 45, Fire Protection for Laboratories Using Chemicals. LC50: the concentration of a vapor or gas that will kill 50% of a test population. Exposure periods are typically for one hour unless otherwise stated. Low Hazard Chemicals6: chemicals that have an NFPA flammability rating of “0” or “1”; a health hazard rating of “0” or “1”; a reactivity rating of “0”; and no special hazard rating such as “oxidizer”, “water reactive”, or “hazardous polymerization” per NFPA 704, Identification System for Fire Hazards of Materials. Marking: a descriptive name, identification number, instructions, cautions, weight, specification, or UN marks, or combinations thereof, required on outer packaging of hazardous materials. MSDS7: Material Safety Data Sheet. Munitions List8: articles, services, and related technical data designated as defense articles and defense services by the Arms Export Control Act of 1968, as amended. Items are listed in the International Traffic in Arms Regulation (ITAR) (22CFR121), published by the U.S. Department of State. nCi/g: Nanocuries per gram. NFPA Health Hazard Rating of "3" (for a gas): per NFPA 704, "Identification of the Hazards of Materials for Emergency Response", any gas whose LC50 (see definition) for acute inhalation toxicity is greater that 1000 ppm but less than or equal to 3000 ppm. NFPA Health Hazard Rating of "4" (for a gas): per NFPA 704, "Identification of the Hazards of Materials for Emergency Response", any gas whose LC50 for acute inhalation toxicity is less than or equal to 1000 ppm. No Commercial Value: an item has “no commercial value” when it has neither utility nor monetary value, as an item or as scrap (see definition).

6 Low Hazard Chemical: This definition refers to the NFPA 704 hazard identification numbers, which includes information on how to use them to determine if a chemical is a “low hazard” chemical. A well-developed set of criteria is needed in order to determine appropriate ratings for those chemicals that have not been rated. Criteria for these ratings have been well defined in NFPA 704. Those criteria can be used to determine hazard ratings for chemicals that have yet to be evaluated. (While other rating systems exist, none is as well- accepted nor does any have criteria that are as well defined for the evaluation of chemicals as does the NFPA 704 system.) It should be noted, however, that NFPA 704 criteria are developed for acute exposures only. Chronic effects, such as carcinogenicity, should be factored into any evaluation when determining health ratings. Information concerning chronic health hazards can be found in numerous resources such as Tomes®, the ACGIH “Guide to Occupational Exposure Threshold Limit Values”, and the NIOSH “Pocket Guide to Chemical Hazards”. 7 Material Safety Data Sheets (MSDS): Although a manufacturer may provide an MSDS for a chemical, the issuance of that MSDS does not necessarily indicate that the material is hazardous. Some manufacturers develop MSDSs for all their chemicals whether the material is hazardous or not. 8 The U.S. Munitions List includes military explosives, propellants, toxicological agents, etc. DOE-HDBK-1139/3-2005 xv Non-Appropriated Fund Property: property (i.e., chemicals) procured without the use of Federal government funds. Nonfriable Asbestos Materials: materials that contain asbestos which is bonded or otherwise rendered unavailable for release into the atmosphere through normal usage and that cannot, when dry, be crumbled, pulverized, or reduced to powder by hand pressure. However, cutting, sanding, crushing, or performing some other disruptive action on items containing nonfriable asbestos can release asbestos fibers into the air. Nuclear Suppliers Group: a select group of nuclear supplier countries dedicated to nuclear nonproliferation that establishes the Trigger List (see definition) and Dual-use List (see definition) in formulating guidelines for the export of nuclear materials, equipment and technology and for the transfer of nuclear-related dual-use nuclear equipment, materials, software and related technology, respectively. Ozone Depleting Substances: Certain chemical substances that, Public Law 101-549, the Clean Air Act Amendments of 1990 identifies as those chemicals, the use of which are primarily responsible for depletion of the earth’s ozone layer. ODS chemicals are also designated in the 1989 Montreal Protocol on Substances that Deplete the Ozone Layer. ODS, Class I Substance: any substance designated as class I by EPA pursuant to 42 U.S.C. 7671(a), including, but not limited to, chlorofluorocarbons, halons, carbon tetrachloride and methyl chloroform. ODS, Class II Substance: any substance designated as class II by EPA pursuant to 42 U.S.C. 7671(a), including, but not limited to, hydrochlorofluorocarbons. Onsite: any area within the boundaries of a DOE site or facility to which access is controlled. [NOTE: If hazardous chemicals are transported over a public road that is on-site, DOT Hazardous Materials Transportation Regulations must be adhered to.]

Operational Emergencies: include the spectrum of significant emergency events or conditions that involve or affect facilities and activities by causing or having the potential to cause serious health and safety impacts onsite or offsite to workers or the public, serious detrimental effects on the environment, direct harm to people or the environment as a result or degradation of security or safeguards conditions or release (or loss of control) of hazardous materials. Oxidizer: as per 29CFR1910.1200, a chemical other than a blasting agent or explosive as defined in 29CFR1910.109(a), that initiates or promotes combustion in other materials, thereby causing fire either of itself or through the release of oxygen or other gases. Outdoor Storage Locker: a moveable, prefabricated structure, manufactured at a site other than the final location of the structure and transported completely assembled or in a ready to assemble package to the final location. It is intended to meet local, state, and federal requirements for the outside storage of hazardous materials. PCB Items: materials containing 50 through 499 ppm PCB. DOE-HDBK-1139/3-2005 xvi Personal Property: property of any kind, except for real estate and interests therein (such as easements and rights-of-way), and permanent fixtures which are Federal government-owned, chartered, rented, or leased from commercial sources by, and in the custody of, DOE or its designated contractors; source, byproduct, special nuclear materials, and atomic weapons as defined in section 11 of the Atomic Energy Act of 1954 (42 U.S.C. 2014), as amended; and petroleum in the Strategic Petroleum Reserve and the Naval Petroleum Reserves. For purposes of this document, personal property means chemicals/chemical products. Pollution Prevention: any action that reduces or eliminates the generation of waste, the release of pollutants to the environment, and the use of certain ODSs. Polychlorinated biphenyls: a class of chlorinated aromatic compounds that is hazardous to human health and the environment. [NOTE: In 41CFR101-42.1102-2, the same acronym “PCBs” is used to mean substances containing polychlorinated biphenyls at a concentration of 500 ppm or greater.]. Precious Metals: a term that refers to gold, silver, and the platinum group metals -- platinum, palladium, rhodium, iridium, ruthenium and osmium. Process Hazard Analysis: hazard evaluation as defined in 29CFR1910.119, “Process Safety Management of Highly Hazardous Chemicals”, subsection (e). Process Safety Management (PSM): the application of management principles, methods, and practices to prevent and control accidental releases of process chemicals or energy. Proliferation-sensitive Property: nuclear-related or dual-use equipment, material, or technology as described in the Nuclear Suppliers Group (see definition) Trigger List (see definition) and Dual-use List (see definition), or equipment, material or technology used in the research, design, development, testing, or production of nuclear or other weapons. Proliferation-sensitive Property is a category under High Risk (Personal) Property (see definition). Property Act: the Federal Property and Administrative Services Act of 1949 (63 Stat. 377), as amended (codified, as amended, in various sections of Titles 40 and 41 of the United States Code), the law that centralized Federal property management and disposition functions under the GSA.

Public Agency: any State, political subdivision thereof, including any unit of local government or economic development district; any department, agency, or instrumentality thereof, including instrumentalities created by compact or other agreement between States or political subdivisions; multi-jurisdictional sub-state districts established by or pursuant to State law; or any Indian tribe, band, group, pueblo, or community located on a State reservation. Public Body: any department, agency, special purpose district, or other instrumentality of a State or local government; any Indian tribe; or any agency of the Federal government. Regulated Area: an area where entry and exit is restricted and controlled. Release: any spilling, leaking, pumping, pouring, emitting, emptying, discharging, injecting, escaping, leaching, dumping, or disposing into the environment (including the abandonment or DOE-HDBK-1139/3-2005 xvii discarding of barrels, containers, and other closed receptacles) of any chemical, extremely hazardous substance (see definition), or CERCLA hazardous substance. Reportable Excess Property: excess property that is reportable to the GSA by the holding agency (see definition) on Standard Form 120, excluding Hazardous Waste (see definition), Extremely Hazardous Property (see definition), Scrap (see definition), Controlled substances, Chemicals determined to be appropriate for abandonment or destruction, Nuclear-related and Proliferation- sensitive Property (see definition), National security-sensitive property, NRC-controlled materials, etc. Reportable excess property includes non-hazardous chemicals, drugs and reagents other than controlled substances; nonfriable asbestos materials, excluded PCB products (i.e., those containing less than 49 ppm PCBs), etc.. Reportable Property: excess or surplus property that is reportable to the GSA by the holding agency (see definition) or receiving organization on an appropriate Standard Form to effect a disposition transaction or to initiate the next phase of screening. Resource Conservation and Recovery Act (RCRA): the Solid Waste Disposal Act, as amended by the Resource Conservation and Recovery Act of 1976, as amended, 42 U.S.C. section 6901 et seq.. Safety Can: approved container of not more than five (5) gallon capacity having a spring closing lid and a spout cover and so designed that it will safely relieve internal pressure when subjected to fire exposure. Safety Officer (designated as Hazardous Materials Branch Safety Officer in NFPA regulations): ensures that recognized safe practices are followed and provides other technical safety advice as needed. Scrap: property that has no value except for its basic material content. Screening Period: the period in which excess or surplus personal property is made available for excess transfer or surplus donation to eligible recipients. Segregated warehouse: a separated or detached building used specifically for warehousing-type operations. Senior Program Official or Designee: controls the acquisition and production of heavy water for a given program. Shelf-Life: the length of time an age-sensitive material can be stored under prescribed conditions and can still confidently retain its properties such that it will function as intended when being put into service. Shelf-Life Item: any item that deteriorates over time or has unstable characteristics such that a storage period must be assigned to assure the item is issued within that period to provide satisfactory performance. Management of such items is governed by 41CFR101-27.2, and by DOD instructions, for executive agencies and DOD respectively.

DOE-HDBK-1139/3-2005 xviii Sprinklered Area: an area that has an overhead system designed and installed according to NFPA 13, "Standard for the Installation of Sprinkler Systems" to spray water down from sprinkler heads during a fire. Standard Form: used for implementing a disposition action or for reporting purposes. State Agency for Surplus Property (SASP): the agency designated under State law to receive Federal surplus personal property for distribution to eligible donees (see definition) within the State as provided for in subsection 203(j) of the Property Act (40 U.S.C. 484(j)). Storage: a chemical(s) set aside for future use or safekeeping or an inventory of compressed or liquefied gases in containers that are not in the process of being used, examined, serviced, refilled, loaded, or unloaded. Surplus Chemicals: any excess chemicals that remain with the facility after having undergone internal screening for reutilization within the DOE complex as well as excess screening for transfer to another Federal Agency. Surplus Property (Surplus): excess personal property no longer required by the Federal agencies as determined by GSA. Surplus Release Date: the date on which screening of excess chemicals for Federal use is completed and the chemicals are not needed for any Federal use. On that date, excess chemicals become surplus and are eligible for donation to non-federal recipients. Suspect (Property): any material or property that cannot be guaranteed, without further evaluation, of being free from chemical or radioactive contamination. Superfund or Superfund Act: common name for CERCLA (Comprehensive Environmental Response, Compensation, and Liability Act of 1980, as amended). System: piping, pumps and/or containers that are attached together so that the collection can perform some specific function. Threshold planning quantity (TPQ): the minimum amount of a substance present at a site at which notification is required under 40CFR355. TPQs are listed in appendices A and B of that regulation. Threshold Quantity (TQ): the minimum amount of a toxic, reactive, or flammable chemical judged by OSHA as capable of causing a catastrophic event. The threshold quantity triggers application of the PSM Rule’s requirements. Toxic gas: any gas that has a National Fire Protection Association (NFPA) health hazard rating of 3 or 4 (see definition) per NFPA 704, Identification System for Fire Hazards of Materials. Transuranic Waste: Transuranic waste (TRU waste) contains alpha-emitting radionuclides with the following characteristics: atomic number greater than 92, half-life greater than 20 years, concentrations greater than 100 nCi/g (see definition.). DOE-HDBK-1139/3-2005 xix Trigger List9: a compilation of Nuclear materials, equipment, and related technology developed by the Nuclear Supplier Group (see definition) and maintained by the International Atomic Energy Agency (IAEA), as Information Circular INFCIRC 254, Part 1. Items on this list "trigger" the imposition of International Atomic Energy Agency safeguards. Type I Items: non-extendable shelf-life items that have a definite storage life after which the item or material is considered to be no longer usable for its primary function and should be discarded. Examples of Type I items include drugs and medicines with certain characteristics, and unstable/reactive chemicals (see definition).

Type II Items: extendable shelf-life items for which successive re-inspection dates can be established when the items or materials have a continued usability as determined by examination based upon criteria that have been agreed upon. Examples of Type II items include paints, coatings and inks. UL Listed: listed by the Underwriter’s Laboratory to indicate special construction requirements have been met. Universal Waste: any of the following hazardous wastes that are managed under the universal waste requirements of 40CFR273: (1) Batteries as described in 40CFR273.2; (2) Pesticides as described in 40CFR273.3; (3) Thermostats as described in 40CFR273.4; and (4) Lamps as described in 40CFR273.5. Unstable/Reactive Chemical: a chemical that in the pure state, or as produced or transported, will vigorously polymerize, decompose, condense, become self-reactive, or otherwise undergo a violent chemical change under conditions of shock, pressure or temperature. Such chemicals may also be identified as Type I items (see definition). Examples include explosives, reactive monomers, and peroxide formers that produce unstable highly friction-sensitive or shock- sensitive peroxides, etc.. Upright Position: the position a cylinder is in when the valve is located at a position higher than any other on the tank. Water Reactive Material: a substance that will spontaneously react with water to release toxic gases, flammable gases, or amounts of heat that could become significant (e.g., resulting in splattering, pressure-volume explosions). It includes those materials that can form explosive mixtures with water. 9 The Trigger List includes nuclear grade graphite, deuterium and heavy water. DOE-HDBK-1139/3-2005 xx Acronyms and Abbreviations ACGIH: American Conference of Governmental Industrial Hygienists. AL: Acquisition Letter. ANSI: American National Standards Institute. ATF: Bureau of Alcohol, Tobacco and Firearms. CERCLA: the Comprehensive Environmental Response, Compensation and Liability Act of 1980 (also known as “Superfund”), as amended. CGA: Compressed Gas Association. CFR: Code of Federal Regulations. CSA: Controlled Substances Act LEPC: Committee or Local Emergency Planning Committee. CRD: Contractor Requirements Document. DOD: U.S. Department of Defense. DOE: U.S. Department of Energy. DOE-PMR: Department of Energy Property Management Regulations, 41CFR109. DOT: U.S. Department of Transportation. DPMO: Departmental Property Management Officer. EADS: Energy Asset Disposal System. EMS: Environmental Management System. EO: Executive Order. EPA: U.S. Environmental Protection Agency. EPCRA: Emergency Planning and Community Right-To-Know Act of 1986, Title III of the Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA)/Superfund Act of 1980. FEDS: Federal Disposal System. FM: Factory Mutual. DOE-HDBK-1139/3-2005 xxi FMR: Federal Management Regulation, (Title 41, Subtitle C), 41CFR102. FPMR: Federal Property Management Regulations, (Title 41, Subtitle C), 41CFR101 to 200. FSC: Federal Supply Classification (as described in the Federal Standard 313). GSA: General Services Administration. HAZMAT: Hazardous Materials Response Team. HMIS: Hazardous Material Information System, sponsored and maintained by the Department of Defense. HSWA: The Hazardous and Solid Waste Amendments of 1984 to RCRA. IC: Incident Commander. ICS: Incident Command System. ISMS: Integrated Safety Management System.

LEPC: local emergency planning committee. MSDS10: Material Safety Data Sheet. NFPA: National Fire Protection Association. NIOSH: National Institute for Occupational Safety and Health. NNSA: National Nuclear Security Administration. NRC: Nuclear Regulatory Commission. ODS: Ozone Depleting Substances. OPMO: Organizational Property Management Officer. OSHA: Occupational Safety and Health Administration. P2: Pollution Prevention. PCBs: polychlorinated biphenyls. PHA: Process Hazard Analysis. 10 Material Safety Data Sheets (MSDS): Although a manufacturer may provide an MSDS for a chemical, the issuance of that MSDS does not necessarily indicate that the material is hazardous. Some manufacturers develop MSDSs for all their chemicals whether the material is hazardous or not. DOE-HDBK-1139/3-2005 xxii RCRA: Resource Conservation and Recovery Act. ROI: Return-On-Investment. SARA: Superfund Amendments and Reauthorization Act of 1986 (see definition). SASP: State Agency for Surplus Property (see definition). SF: Standard Form. TBD: to be determined at a later date. TRU: Transuranic Waste. TSCA: Toxic Substances Control Act (15 U.S.C. 2601 – 2692). USC: United States Code. USCS: United States Code Service DOE-HDBK-1139/3-2005 xxiii INTENTIONALLY BLANK DOE-HDBK-1139/3-2005 1 Chapter 1 - Hazard Analysis 1.0 Introduction This chapter identifies and consolidates existing user safety and health requirements found in DOE and Federal chemical-related safety and health regulations and National Standards that address hazard analysis of activities involving chemicals (see definition) and chemical products (see definition). State and local codes and requirements are NOT included. This chapter specifically consolidates requirements found in the National Fire Protection Association (NFPA), the American National Standards Institute (ANSI), the Compressed Gas Association (CGA), the Occupational Safety and Health Administration (OSHA), and certain Environmental Protection Agency (EPA) regulations and Department of Energy (DOE) Rules and Orders, including technical standards that are made mandatory by their specific reference within a regulation, rule or DOE Order. This chapter is intended to list chemical-related safety and health requirements and to consolidate those that are overlapping and/or duplicative. The list of requirements includes “pointers” to the sources of those requirements. This document does NOT create any new or additional requirements. 2.0 Applicability The information presented here applies to all locations that use chemicals or chemical products. [NOTE: Throughout this document, the term “chemicals” is used to indicate chemicals and/or chemical products as described in Section 3, below.] This chapter is intended only to address safety and health-related hazard and risk analysis requirements applicable to chemical user activities. It consolidates existing, core safety and health requirements that all sites must follow when engaged in chemical-related activities. The requirements included in this chapter come from sources that have different safety purposes. As a result, some of these requirements may not always be applicable to the work being performed at an individual site or facility. It is the responsibility of each user to determine the applicability of specific requirements to their work and how they are implemented. The reference sources for the requirements included in this chapter can be used to determine the applicability of those requirements to the work being performed.

3.0 Definitions and Acronyms See Glossary. 4.0 Requirements for Chemical Hazard Analysis Sources11 Consolidated Requirements 12 11 Hyperlinks to ANSI, CGA, and NFPA requirements provided here are for general information only, as they require user subscription to a prescribed service in order to access these organizations’ source requirements. 12 PL 91-596, section 6(a), the General Duty Clause of the Occupational Safety and Health Act of 1970, requires employers to protect their employees from all recognized hazards in the workplace and is a general requirement applicable to all operations/activities involving chemicals. DOE-HDBK-1139/3-2005 2 Sources11 Consolidated Requirements 12 4.1 General (Applicable to all operations/activities involving chemicals) ANSI Z49.1, 3.2.2.2; CGA P-1, 4.1; DOE 440.1A , 4(i); NFPA 30, 5.2; NFPA 45, 7.1; NFPA 45, 7.2.1.1, NFPA 430, 2.-1.1; NFPA 432, 4.7.1; 10CFR835.204(d)(2); 29CFR1910.106(e)(8); 29CFR1910.146(c)(1)- (d)(2); 29CFR1910.1450(e)(3); 48CFR970.5204-2(c)(2)13 4.1.1 Hazards associated with all activities involving chemicals that could put the employee at risk of injury or illness shall be evaluated. Those activities include, but are not limited to a) design of new facilities or modification of existing facilities and equipment, b) operations and procedures and c) equipment, products and services that are selected or purchased. [NOTE: Numerous other substance-specific hazard analysis requirements can be found in 29CFR1910, Subpart Z] DOE O 440.1A, Attachment 1 (1)(b)(2)(d) and Attachment 2 (14)(a)(4); NFPA 430, 2.1.1; NFPA 430, 2.10.1; NFPA 432, 4.7.1; 29CFR1910.132(d)(2) 4.1.1.1 The results of the hazard analysis shall be documented and approved by the appropriate safety official or manager. ANSI Z49.1, 3.2.1.2; ANSI Z49.1, 3.2.1.3; ANSI Z49.1, 3.2.1.5; CGA P-1, 4.1; NFPA 45, 7. 1; NFPA 430, 2.7.1; NFPA 432, 4.2; 29CFR1910.1200(h)(1); 29CFR1910.1450(f)(1) and (f)(4)(i)(B) and (f)(4)(i)(C); 29CFR1926.21(b)(2) 4.1.2 Before beginning work, employees shall be informed of the hazards present in their work area. 13 This requirement of the DOE Acquisition Regulations (DEAR, ES&H Clause) requires an identification and evaluation of hazards associated with work, as part of an overall documented safety management system. DOE-HDBK-1139/3-2005 3 Sources11 Consolidated Requirements 12 4.2 Hazardous Operations14 (see definition) DOE O 151.1A, Attachment, Chap. IV, 3(a)(1); DOE O 420.1A, 4.2.1 (5); 10CFR830, Subpart B; 10CFR850.21(a); 10CFR1021.400; 29CFR1910.119(e); 29CFR1910.120(c)(1); 40CFR68.50; 40CFR68.67(a); 40CFR1502.14 4.2.1 Hazardous processes shall be analyzed for possible natural and man-made events that could lead to or result in a loss of control of hazardous materials DOE-STD-1120-98; DOE-STD-3009-94; DOE-STD-3011-94; DOE-STD-3016-99; DOE O 460.1A; DOE O 460.1B [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A]; 10CFR830.7; 10CFR830 Subpart B, 204(a) and (b); 29CFR1910.119(e)(2); 40CFR68.67(b); 40CFR1502.24 4.2.1.1 Hazard analysis techniques shall be selected and used that are appropriate for the hazards and complexities of work processes being analyzed DOE-STD-1027-92; 10CFR830 Subpart B, Part202(b)(3); 29CFR1910.119(d); 29CFR1910.120(c)(3); 40CFR68.65; 40CFR1502.15 4.2.1.2 Process information relevant to the hazard analysis, such as energy sources and hazardous materials, shall be identified DOE O 5480.23, 8(c)(3); 10CFR830.204(b)(3);

4.2.1.3 Consequences of postulated accidents associated with hazardous processes and their likelihood of occurrence shall be evaluated 14 The requirements for hazardous operations are in addition to requirements associated with those activities specified in Section 4.1. DOE-HDBK-1139/3-2005 4 Sources11 Consolidated Requirements 12 29CFR1910.119(e)(3); 29CFR1910.120(c)(7); 40CFR68.22; 40CFR68.25; 40CFR68.28; 40CFR68.67(c); 40CFR1502.16; 40CFR1508.8 10CFR850.21(b); 29CFR1910.119(e)(4); 40CFR68.67(d) 4.2.1.4 Hazard analyses shall be performed by qualified personnel 10CFR1021.310; 10CFR830 Subpart B, 204(a) and (b); 29CFR1910.119(e)(5); 29CFR1910.120(b)(4); 40CFR68.39; 40CFR68.67(e); 40CFR1508.10 4.2.1.5 Results of hazard analyses shall be documented and approved by appropriate management 10CFR830 Subpart B, 204(c)(1) and (c)(2); 29CFR1910.119(e)(6); 40CFR68.67(f) 4.2.1.6 Hazard analyses shall be updated and revalidated periodically 10CFR830.6; 29CFR1910.119(e)(7); 40CFR68.67(g) 4.2.1.7 Hazard analysis results and documentation, including updates, shall be retained for the life of the process operation 5.0 Source Documents ANSI Z49.1 (1994), “Safety in Welding, Cutting, and Allied processes”. CGA P-1 (2000), “Safe Handling of Compressed Gases in Containers”. DOE O 151.1, “Comprehensive Emergency Management System”. DOE O 420.1A, “Facility Safety”. DOE O 440.1A, “Worker Protection Management for DOE Federal and Contractor Employees”. DOE O 460.1A, “Packaging and Transportation Safety”. DOE O 460.1B, “Packaging and Transportation Safety” [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A]. DOE-HDBK-1139/3-2005 5 DOE-STD-1027-92, “Hazard Categorization and Accident Analysis Techniques for Compliance with DOE O 5480.23, Nuclear Safety Analysis Reports”. DOE-STD-1120-98, “Integration of Environment, Safety, and Health into Facility Disposition Activities”. DOE-STD-3009-94, “Preparation Guide for U.S. DOE Nonreactor Nuclear Facility Safety Analysis Reports”. DOE-STD-3011-94, “Guidance for Preparation of DOE 5480.22 (TSR) and DOE 5480.23 (SAR) Implementation Plans”. DOE-STD-3016-99, “Limited Standard; Hazard Analysis Reports for Nuclear Explosive Operations”. NFPA 30 (2000), “Flammable and Combustible Liquids Code”. NFPA 45 (2000), “Standard on Fire Protection for Laboratories Using Chemicals”. NFPA 430 (2000), “Storage of Liquid and Solid Oxidizers”. NFPA 432 (2002), “Storage of Organic Peroxides Formulation”. P.L. 91-596, Sec. 6(a), “General Duty Clause” of the Occupational Safety and Health Act of 1970 10CFR830, “Nuclear Safety Management,” Subpart B, “Safety Basis Requirements”. 10CFR835, “Occupational Radiation Protection”. 10CFR850, “Chronic Beryllium Disease Prevention Program”. 10CFR1021, “National Environmental Policy Act Implementing Procedures”. 29CFR1910.106, “Flammable and Combustible Liquids”. 29CFR1910.119, “Process Safety Management of Highly Hazardous Chemicals”. 29CFR1910.120, “Hazardous Waste Operations and Emergency Response”. 29CFR1910.132, “Personal Protective Equipment”. 29CFR1910.146, “Permit-required Confined Spaces”. 29CFR1910.1200, “Hazard Communication”. 29CFR1910.1450, “Occupational Exposure to Hazardous Chemicals in Laboratories”. 29CFR1926.21, ”Safety Training and Education”. 40CFR68, “Chemical Accident Prevention Provisions”. 40CFR1500-1508, “Chapter V-Council on Environmental Quality”. 48CFR970, “DOE Management and Operating Contracts”. DOE-HDBK-1139/3-2005 6 INTENTIONALLY BLANK

DOE-HDBK-1139/3-2005 7 Chapter 2 – Acquisition 1.0 Introduction This chapter identifies and consolidates existing user safety and health requirements found in DOE and Federal chemical-related safety and health regulations and National Standards that address the acquisition of chemicals (see definition) and chemical products (see definition). State and local codes and requirements are NOT included. This chapter specifically consolidates requirements found in the National Fire Protection Association (NFPA), the Occupational Safety and Health Administration (OSHA), the Bureau of Mines, the Bureau of Alcohol, Tobacco and Firearms and certain Environmental Protection Agency (EPA) regulations and Department of Energy (DOE) Rules and Orders, including technical standards that are made mandatory by their specific reference within a regulation, rule or DOE Order. Direct requirements for acquisition are found in “Federal Acquisition Regulations” (FAR) and “Department of Energy Acquisition Regulations” (DEAR). In addition, there are many regulations and standards that include implied requirements for the acquisition of chemicals and chemical products. Therefore, implied requirements are summarized here but are not included as mandatory requirements in this chapter. Requirements for on-site transportation of chemicals and chemical products can be found in Chapter 4 of this document. This chapter is intended only to consolidate overlapping and/or duplicative chemical-related safety and health requirements. The listing of consolidated chemical-related safety and health requirements contained here includes “pointers” to the sources of those requirements, showing the user what the requirements are and where each comes from. The procurement requirements in chapter 7 should also be referenced. This document does NOT create any new or additional requirements. 2.0 Applicability The information presented here applies to all locations that purchase or use chemicals, chemical products or services that involve the use of chemicals or chemical products. [NOTE: Throughout this chapter, the term “chemicals” is used to indicate chemicals and/or chemical products as described in Section 3, below.] This chapter consolidates existing, core safety and health requirements that all sites must follow when engaged in chemical-related activities. The requirements included in this chapter come from sources that have different safety purposes. As a result, some of these requirements may not always be applicable to the work being performed at an individual site or facility. It is the responsibility of each user to determine the applicability of specific requirements to their work and how they are implemented. The reference sources for the requirements included in this chapter can be used to determine the applicability of those requirements to the work being performed. 3.0 Definitions and Acronyms See Glossary. DOE-HDBK-1139/3-2005 8 4.0 Requirements for the Acquisition of Chemicals Sources11 Consolidated Requirements12 4.1 General (Applicable to all acquisitions involving chemicals) DOE O 440.1A , 4(i); 48CFR970.5223-1 4.1.1 Hazards associated with all activities involving chemicals that could put the employee at risk of injury or illness shall be identified and evaluated before purchase. 10CFR1021; 48CFR970.5223-2 4.1.2 Substitution of materials that are less hazardous and/or have less of an environmental impact shall be evaluated before purchase.

DOE O 460.1A , 4(i); DOE O 460.1B [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A] 4.1.3 Packaging and Transportation Safety requirements shall be addressed as a part of the acquisition process. NFPA 45 7.1 4.1.4 When a chemical is ordered, its hazards shall be determined and that information shall be provided to those who receive, store, use, or dispose of the chemical. Restrictions imposed by local governmental regulations and in-house rules shall be followed. 29CFR1910.1200(g)(6)( iii); 29CFR1910.1200(g)(8); 29CFR1910.1450(f)(3)(v) 4.1.5 The manufacturer’s Material Safety Data Sheet shall be obtained for all new chemical purchases and shall be made readily available to those who receive, store, use or dispose of the chemicals. In laboratories subject to 29CFR1910.1450, other reference materials may be used. Additional Procurement Requirements (Non Health and Safety Requirements are provided for Informational purposes) 4.2 Alcohol 27CFR22.41; 48CFR908.7107 4.2.1 Applications to purchase tax free alcohol shall be submitted to the ATF. 4.3 Helium The Helium Act (Pub. L. 86-777, as amended (50 U.S.C. 167(d)); 30CFR602; 48CFR908.7108; 49 FR 11945 (3/28/84), as amended; 59 FR 9105 (2/25/94) 4.3.1 DOE and its authorized contractors shall, to the extent that supplies are readily available, whether in gaseous or liquid form, purchase all major requirements large quantities of helium from the Secretary of Interior, Bureau of Mines, or from the Bureau of Mines distribution contractors eligible to sell Bureau of Mines helium to Federal agencies. The purchase document shall contain the following statement: "Helium furnished under this contract shall be Bureau of Mines Helium." DOE-HDBK-1139/3-2005 9 Sources11 Consolidated Requirements12 4.4 Fuel and Petroleum 41CFR101-26.602; 48CFR908.7109 4.4.1 Acquisitions of fuel and packaged petroleum products by DOE offices and contractors shall be from Defense sources. 41CFR101-26.602; 48CFR908.7110 1.1.8 4.4.2 DOE offices and authorized contractors may participate in the Defense Fuel Supply Center (DFSC) coal- contracting program for carloads or larger lots. 4.5 Arms and Ammunition 48CFR908.7111; 49 FR 11945, Mar. 28, 1984, as amended at 49 FR 38950, Oct. 2, 1984 4.5.1 Acquisition of arms and ammunition readily procurable in the civilian market shall be made in accordance with local site acquisition procedures. 4.6 DOE-specific materials acquisitions15 Contracting activities shall require authorized contractors to obtain the special materials identified in the following subsections in accordance with the procedures stated therein. 48CFR908.7121 4.6.1 Heavy water. The Senior Program Official or designee controls the acquisition and production of heavy water for a given program. Requests for the acquisition or production of heavy water orders shall be placed directly with the cognizant Senior Program Official or designee (see definition). 54 FR 27646, June 30, 1989, as amended at 59 FR 9105, Feb. 25, 1994; 62 FR 2312, Jan. 16, 1997 4.6.2 Precious metals16. DOE offices and authorized contractors shall coordinate with the Oak Ridge operating contractor regarding the availability of the above metals prior to the purchase of these metals on the open market. 62 FR 2312, Jan. 16, 1997 4.6.3 Lithium17. The DOE Oak Ridge Operations Office supplies of Lithium shall be considered the first source of supply prior to procurement of lithium compounds from any other source.

15 This section covers the purchase of materials peculiar to the DOE program. While purchases of these materials are unclassified, the specific quantities, destination or use may be classified. See appropriate sections of the Classification Guide. 16 The DOE Oak Ridge Operations Office is responsible for maintaining the DOE supply of precious metals. These metals are platinum, palladium, iridium, osmium, rhodium, ruthenium, gold, and silver. 17 Lithium is available at no cost other than normal packing, handling, and shipping charges from the DOE Oak Ridge Operations Office. DOE-HDBK-1139/3-2005 10 Sources11 Consolidated Requirements12 21CFR1316 4.7 Controlled Substances Use of controlled substances in research requires a permit or license. 5.0 Source Documents DOE O 440.1A, “Worker Protection Management”. DOE O 460.1A, “Packaging and Transportation Safety”. DOE O 460.1B, “Packaging and Transportation Safety” [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A]. The Helium Act (Pub. L. 86-777, as amended (50 U.S.C. 167(d). NFPA 45 (2000)“Standard on Fire Protection for Laboratories Using Chemicals”. 10CFR1021, “National Environmental Policy Act Implementing Procedures”. 21CFR1316, “Drug Enforcement Administration; Administrative Functions, Practices, and Procedures”. 27CFR22.41, “Distribution and Use of Tax-Free Alcohol, Qualification”. 29CFR1910.1200, “Occupational Safety and Health Standards – Hazard Communication”. 29CFR1910.1450, “Occupational Safety and Health Standards – Occupational Exposure to Hazardous Chemicals in Laboratories”. 30CFR602, Bureau of Mines, Department of the Interior - Chapter VI - Subchapter A--Helium and Coal”. 41CFR101-26.602, ” Federal Property Management Regulations - Procurement Sources and Program”. 48CFR, “Department of Energy Acquisition Regulations”. [49 FR 11945, Mar. 28, 1984, as amended at 49 FR 38950, Oct. 2, 1984]. [49 FR 11945, Mar. 28, 1984, as amended at 59 FR 9105, Feb. 25, 1994]. [54 FR 27646, June 30, 1989, as amended at 59 FR 9105, Feb. 25, 1994]. [62 FR 2312, Jan. 16, 1997]. DOE-HDBK-1139/3-2005 11 Chapter 3 - Chemical Inventory and Tracking 1.0 Introduction This chapter identifies and consolidates existing user safety and health requirements found in DOE and Federal chemical-related safety and health regulations and National Standards that address the inventory and tracking of chemicals (see definition) and chemical products (see definition). State and local codes and requirements are NOT included. This chapter specifically consolidates requirements found in the Occupational Safety and Health Administration (OSHA), and certain Environmental Protection Agency (EPA) regulations and Department of Energy (DOE) Rules and Orders, including technical standards that are made mandatory by their specific reference within a regulation, rule or DOE Order. Direct requirements for an inventory and tracking system are found in OSHA’s regulation 29CFR1910.1200, and EPA’s 40CFR370.25. In addition, there are many regulations and standards for which an inventory and tracking system is an implied requirement, since inventory information facilitates compliance. Therefore, implied requirements are summarized here but are not included as mandatory requirements in this chapter. This chapter is intended to list chemical-related safety and health requirements and to consolidate those that are overlapping and/or duplicative. The list of requirements includes “pointers” to the sources of those requirements.

This document does NOT create any new or additional requirements. 2.0 Applicability The information presented here applies to all locations that use or store chemicals or chemical products. It applies to chemicals prior to their becoming waste (See Disposition, Chapter 9, for requirements for the disposition of chemicals and chemical products.) [NOTE: Throughout this document, the term “chemicals” is used to indicate chemicals and/or chemical products as described in Section 3, below.] This chapter consolidates existing, core safety and health requirements that all sites must follow when engaged in chemical-related activities. The requirements included in this chapter come from sources that have different safety purposes. As a result, some of these requirements may not always be applicable to the work being performed at an individual site or facility. It is the responsibility of each user to determine the applicability of specific requirements to their work and how they are implemented. The reference sources for the requirements included in this chapter can be used to determine the applicability of those requirements to the work being performed. 3.0 Definitions and Acronyms See Glossary. 4.0 Requirements for Chemical Inventory and Tracking [NOTE: The information that follows is a consolidation of existing federal safety and health requirements and national standards that relate to the inventorying and tracking of chemicals. It DOE-HDBK-1139/3-2005 12 therefore contains "shall" statements that are taken from, or based on "shall" statements in those existing requirements. While requirements from national standards that are referenced here are not, in and of themselves, mandatory, they are made mandatory by DOE and federal requirements, including OSHA regulation 29CFR1910.6, which incorporates them by reference. DOE O 440.1A mandates compliance with OSHA regulations found in Title 29 of the Code of Federal Regulations (CFR). National standard requirements referenced here are thereby made mandatory for DOE contractors through contracts that include DOE O 440.1A. Please see the Introduction to this section of the Chemical Management Handbook for more information.] Sources11 Consolidated Requirements12 4.1 Chemical Inventory Requirements 29CFR1910.1200(e)(1) 4.1.1 Maintain a list of the hazardous chemicals known to be present using an identity that is referenced on the appropriate material safety data sheet (the list may be compiled for the workplace as a whole or for individual work areas). [NOTE: Some chemical specific regulations, such as those for Asbestos and Beryllium, may also contain their own inventory tracking requirements.] 40CFR370.25(a) to (d) 4.1.2 The owner or operator of a facility shall annually submit an inventory form (Tier 1 or equivalent State or local form) containing information on specified hazardous chemicals present at the facility during the preceding calendar year above specified threshold levels to the state emergency response commission, the local emergency planning committee, and the fire department with jurisdiction over the facility. For any specific hazardous chemical at the facility, the owner or operator may submit a Tier II form (40CFR371.41) in lieu of the Tier I information. NFPA 45, 7.2.3.3 4.1.3 For laboratories chemical inventories shall be maintained within facility limits.

While requirements from national standards that are referenced here are not, in and of themselves, mandatory, they are made mandatory by DOE and Federal requirements, including OSHA regulation 29CFR1910.6, which incorporates them by reference. DOE O 440.1A mandates compliance with OSHA regulations found in Title 29 of the Code of Federal Regulations (CFR). National standard requirements referenced here are thereby made mandatory for 4.2 Implied Chemical Inventory Requirements. There are many mandatory standards that do not directly require an inventory of hazardous chemicals, but for which use of a chemical inventory and tracking system would be necessary for, or would facilitate compliance. A list of major standards with implied requirements for keeping a chemical inventory and/or for tracking chemicals follows. The applicability of specific DOE Orders will depend on each site’s individual contract. DOE-HDBK-1139/3-2005 13 Sources11 Consolidated Requirements12 DOE contractors through contracts that include DOE O 440.1A. 29CFR1910.38 4.2.1 Employee Emergency Plans and Fire Prevention Plans. Maintain a list of the major workplace fire hazards and their proper handling and storage procedures; potential ignition sources and their control procedures; and the type of fire protection equipment or systems that can control a fire involving the identified hazards. 29CFR1910.1450 4.2.2 Occupational Exposure to Hazardous Chemicals in Laboratories. Requires employee protection for work in laboratory environments with particularly hazardous substances, including carcinogens, reproductive toxins, and substances with a high acute toxicity. Requires an approved Chemical Hygiene Plan covering the tasks, hazards, and controls before beginning the work. Upon assignment, employees must be provided with information and training to ensure that they are apprised of the hazards of chemicals in their work areas. This information and training must be provided to employees prior to the start of any work in the area, including the start-up of any new operation or task. 29CFR1910.1020 4.2.3 Access to Employee Exposure and Medical Records. Authorizes employee access to MSDSs or to a chemical inventory or any other record that may reveal the identity of toxic substances or harmful physical agents and where and when they were used in order to give employees some idea of their potential chemical exposures. DOE O 151.1A 4.2.4 Comprehensive Emergency Management System. Uses a hazard assessment to develop an emergency management program that protects workers, the public, and the environment. Additions or deletions of chemical hazards, or changes in the magnitude of a chemical hazard from an up- to-date chemical inventory can be used in development and maintenance of the emergency management hazards assessment. During an emergency response, a real-time chemical inventory can provide the basis for consequence assessments used for protective action determinations. DOE-HDBK-1139/3-2005 14 Sources11 Consolidated Requirements12 DOE O 440.1A 4.2.5 Worker Protection Management for DOE Federal and Contractor Employees. Mandates an Industrial Hygiene Program with surveys of all work areas and operations to identify and evaluate potential health hazards through appropriate workplace monitoring. A chemical inventory can help to identify locations where chemical health hazards may be present. Managers must ensure that applicable explosives operations comply with DOE M 440.1-1. Requires compliance with OSHA regulations (29CFR1910 and 29CFR1926).

29CFR1910.119 4.2.6 Process Safety Management of Highly Hazardous Chemicals (PSM). Establishes requirements to protect workers by preventing or minimizing the consequences of 1) catastrophic releases of toxic, reactive, or flammable chemicals used in quantities at or above specified thresholds or 2) ignition of explosives in manufacturing processes. Chemical tracking is needed to determine where threshold quantities are exceeded. PSM also requires an employer to keep process safety information on the chemicals used and specify the maximum intended inventory of any listed chemical. DOE O 420.1, Chg 3 4.2.7 Facility Safety. All new construction shall, as a minimum, conform to the Model Building Codes applicable for the state or region, supplemented with additional safety requirements associated with the facility hazards. Inventories of chemicals must be tracked in order to ensure that chemical limits specified in applicable regulations are not exceeded. Local building and fire codes. 4.2.8 Local Codes. Establish requirements for the prevention, control and mitigation of dangerous conditions created by hazardous materials and for providing information needed by emergency response personnel. Permits are required to store, dispense, use or handle quantities of hazardous materials exceeding listed permit amounts. The authority having jurisdiction may require that a Hazardous Materials Management Plan and/or Hazardous Materials Inventory Statement accompany the permit. In addition, inventories of chemicals must be tracked in order to determine whether or not listed permit quantities of chemicals have been exceeded. Each facility is responsible for determining the applicability of their local building and fire codes. DOE-HDBK-1139/3-2005 15 Sources11 Consolidated Requirements12 The DEAR Clause 4.2.9 Department of Energy Acquisition Regulation (DEAR) 970.5204-2, “Integration of Environment, Safety and Health into Work Planning and Execution”. The contractor shall comply with, and assist the Department of Energy in complying with ES&H requirements of all applicable laws and regulations, and applicable directives identified in the clause of this contract on Laws, regulations, and DOE Directives. The contractor shall cooperate with Federal and non-Federal agencies having jurisdiction over ES&H matters under his/her contract. Before work is performed, the associated hazards are evaluated and an agreed-upon set of ES&H standards and requirements are established which, if properly implemented, provide adequate assurance that employees, the public, and the environment are protected from adverse consequences. Administrative and engineering controls to prevent and mitigate hazards are tailored to the work being performed and its associated hazards. Emphasis should be on designing the work and/or controls to reduce or eliminate the hazards and to prevent accidents and unplanned releases and exposures. [See also Safety Management System Policy (DOE P 450.4) and Integrated Safety Management System Guide (DOE G 450.4-1B)]. 10CFR830 4.2.10 Nuclear Safety Management. The documented safety analysis requires a systematic identification of all natural and man-made hazards associated with the facility. Some DOE contracts may still contain the earlier, more general safety analysis Order, Nuclear Safety Analysis Reports (DOE O 480.23), or it’s predecessor, Safety Analysis and Review System (DOE O 481.1B) for non-nuclear facilities. 40CFR68

4.2.11 Chemical Accident Prevention Provisions. Requires offsite consequence analysis, development, and implementation of a Risk Management Plan to protect the public and the environment by preventing or minimizing the consequences of catastrophic releases of toxic, reactive, or flammable chemicals used in quantities at or above specified thresholds. Inventories of chemicals must be tracked in order to ensure that specified chemical limits are not exceeded. 40CFR355 4.2.12 Emergency Planning and Notification. Establishes the list of extremely hazardous substances, threshold planning quantities and facility notification responsibilities necessary for development of state and local emergency response plans. DOE-HDBK-1139/3-2005 16 Sources11 Consolidated Requirements12 40CFR61; 40CFR63 4.2.13 National Emission Standards for Hazardous Air Pollutants (NESHAPs) Standards are provided for specific types of sources and processes involving hazardous air pollutants (including radionuclides). Requires registration of emission sources and quantity of air contaminant emissions. Contains standards for specific processes involving hazardous chemicals. A chemical inventory is needed to identify and track locations and quantities of chemicals that may be released as hazardous air pollutants. 40CFR82 4.2.14 Protection of Stratospheric Ozone. A system to track the acquisition and inventory of ozone depleting substances can be used to accomplish the required annual certification that each ozone depleting substance is being used only for laboratory applications and is not being resold or used in manufacturing. 5.0 Source Documents DEAR 970.5204-2, “Integration of Environment, Safety and Health into Work Planning and Execution”. DOE O 151.1A, “Comprehensive Emergency Management System”. DOE O 420.1 Chg 3, “Facility Safety”. DOE O 440.1A, “Worker Protection Management for DOE Federal and Contractor Employees”. 10CFR830, “Nuclear Safety Management”. 29CFR1910.38, “Employee Emergency Plans and Fire Prevention Plans”. 29CFR1910.119, “Process Safety Management of Highly Hazardous Chemicals”. 29CFR1910.1020, “Access to Employee Exposure and Medical Records”. 29CFR1910.1200, "Hazard Communication". 29CFR1910.1450, “Occupational Exposure to Hazardous Chemicals in Laboratories”. 40CFR61, “National Emission Standards for Hazardous Air Pollutants (NESHAPs)”. 40CFR63, “National Emission Standards for Hazardous Air Pollutants for Source Categories”. 40CFR68, “Chemical Accident Prevention Provisions”. 40CFR82, “Protection of Stratospheric Ozone”. 40CFR355, “Emergency Planning and Notification”. 40CFR370, “Hazardous Chemical Reporting: Community Right-To-Know”. DOE-HDBK-1139/3-2005 17 Chapter 4 - On-Site Chemical Transportation 1.0 Introduction This chapter identifies and consolidates existing user safety and health requirements found in DOE and Federal chemical-related safety and health regulations and National Standards that address the on-site transport of non-radioactive chemicals (see definition) and chemical products (see definition). State and local codes and requirements are NOT included. This chapter specifically consolidates requirements found in DOE O 460.1A and DOE O 460.1B, [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A], Occupational Safety and Health Administration (OSHA) regulations 29CFR1910.101, 29CFR1910.253, and 29CFR1926.350, the American National Standards Institute (ANSI) standard ANSI Z49.1, and the Compressed Gas Association (CGA) Pamphlets G-1 and P-1, including technical standards that are made mandatory by their specific reference within a regulation, rule or DOE Order.

This chapter is intended to list chemical-related safety and health requirements and to consolidate those that are overlapping and/or duplicative. The list of requirements includes “pointers” to the sources of those requirements. This document does NOT create any new or additional requirements. 2.0 Applicability The information presented here applies to all transport of chemicals or chemical products on-site. It includes hazardous materials offered for transportation on-site, and the packaging, labeling or marking of hazardous materials for transportation on-site. Packaging and transportation safety requirements apply to the purchasers of hazardous chemicals if they subsequently transfer those chemicals to another location – for on-site transfers, site rules apply; for off-site transfers, DOT rules apply. [NOTE: Throughout this document, the term “chemicals” is used to indicate chemicals and/or chemical products as described in Section 3, below.] This chapter consolidates existing, core safety and health requirements that all sites must follow when engaged in chemical-related activities. The requirements included in this chapter come from sources that have different safety purposes. As a result, some of these requirements may not always be applicable to the work being performed at an individual site or facility. It is the responsibility of each user to determine the applicability of specific requirements to their work and how they are implemented. The reference sources for the requirements included in this chapter can be used to determine the applicability of those requirements to the work being performed. 3.0 Definitions and Acronyms See Glossary. 4.0 Requirements for On-Site Chemical Transportation Sources11 Consolidated Requirements12 DOE O 460.1A, 4.b; DOE O 460.1B [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A] 4.1 Onsite Hazardous Materials Transfers - shall comply with either: DOE-HDBK-1139/3-2005 18 Sources11 Consolidated Requirements12 49CFR171-179 4.1.1 the Hazardous Materials Regulations (see definition) that cover, but are not limited to, such subjects as: shipper’s responsibilities, shipping papers, packaging, handling, labeling of material containers, marking packages place carding and emergency response information, OR DOE O 460.1A, 4.b; DOE O 460.1B [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A] 4.1.2 the site- or facility-specific Document , from the cognizant Operations or Field Office, that describes the methodology and compliance process to meet equivalent safety for any deviation from the Hazardous Materials Regulations. DOE O 460.1A, 4.b; DOE O 460.1B [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A] 4.1.2.1 For multiple-tenant DOE sites, safety documents for several contractor organizations may be combined into a single document. DOE O 460.1A, 4.b; DOE O 460.1B [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A] 4.1.2.2 DOE-operated sites (specifically, Morgantown and Pittsburgh Energy Technology Centers) may approve their own Transportation Safety Documents. DOE O 460.1A, 4.b; DOE O 460.1B [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A] 4.1.2.3 Approved Transportation Safety Documents shall be in effect no later than 1 year from incorporation of DOE O 460.1A or DOE O 460.1B into the contractor's contracts. 4.2 Specific materials 29CFR1910.101(b) 4.2.1 Compressed Gas Cylinders CGA P-1

4.2.1.1 The in-plant handling of all compressed gases in cylinders, portable tanks, rail cars, or motor vehicle cargo tanks shall be in accordance with the CGA (see definition) P-1. 29CFR1910.253(b)(1)(i); 49CFR171-179 4.2.1.2 All portable cylinders used for the shipment of compressed gases shall be constructed and maintained in accordance with the regulations of the U.S. Department of Transportation, 49CFR171- 179. ANSI Z49.1; 29CFR1910.253(b)(1)(ii) 4.2.1.3 Compressed gas cylinders shall be legibly marked, for the purpose of identifying the gas content, with either the chemical or the trade name of the gas. Such marking shall be by means of stenciling, stamping, or labeling, and shall not be readily removable. Whenever practical, the marking shall be located on the shoulder of the cylinder. DOE-HDBK-1139/3-2005 19 Sources11 Consolidated Requirements12 CGA P-1, 3.4.2; 29CFR1926.350(a)(1) 4.2.1.4 Valve protection caps shall be in place and secured when not in use or being transported. ANSI Z49.1,10.8.3.8; CGA P-1, 3.5; CGA P-1, 3.5.2; 29CFR1926.350(a)(2); 29CFR1910.253(b)(1)(iv) 4.2.1.5 Ropes, chains, or slings shall not be used to suspend cylinders unless provisions have been made on the cylinder for appropriate lifting attachments such as lugs. Where appropriate lifting attachments have not been provided on the cylinder, suitable cradles, sling boards, platforms or pallets to hold the cylinder shall be used for lifting. Lifting attachments or other attachments shall never be welded to cylinders. Cylinders shall not be hoisted or transported by means of magnets or choker slings. 29CFR1926.350(a)(3) 4.2.1.6 Cylinders shall be moved by tilting and rolling them on their bottom edges. They shall not be rolled in the horizontal position or dragged. They shall not be intentionally dropped, struck, or permitted to strike each other violently. CGA P-1, 3.5; 29CFR1926.350(a)(4) 4.2.1.7 A suitable hand truck, forklift, cylinder pallet system, or similar material-handling device shall∗ be used with the container properly secured to the device. When powered vehicles transport cylinders, they shall be secured in a vertical position. ANSI Z49.1, 10.8.3.7; 29CFR1926.350(a)(5) 4.2.1.8 Valve protection caps shall not be used for lifting cylinders from one vertical position to another. Bars shall not be used under valves or valve protection caps to pry frozen cylinders loose. Warm, not boiling, water shall be used to thaw frozen cylinders loose. ANSI Z49.1, 10.8.3.10; 29CFR1926.350(a)(6) 4.2.1.9 Unless cylinders are firmly secured on a special carrier intended for this purpose, regulators shall be removed from the cylinders and valve protection caps put in place before cylinders are moved. ANSI Z49.1, 10.8.3.10; 29CFR1926.350(a)(8) 4.2.1.10 When cylinders are moved at any time, the cylinder valve shall be closed. *The CGA Pamphlet uses the word “should.” Since the DOE incorporates the CGA documents by reference the requirement may be interpreted as mandatory. DOE-HDBK-1139/3-2005 20 Sources11 Consolidated Requirements12 CGA P-1, 4.7.2 4.2.2 Cryogenic liquid containers - In addition to the requirements listed above for other compressed gases, cryogenic liquids must be moved by use of a four-wheeled hand truck designed to move cryogenic liquefied gas containers with a capacity greater than 20 gal (76L). Hand trucks must be kept in good operating condition.

CGA G-1 4.2.3 Acetylene - The in-plant transfer of acetylene in cylinders shall be in accordance with CGA G-1. CGA G-1, 5.1.1 4.2.3.1 Acetylene shall be called by its proper name, “Acetylene.” Acetylene shall not be referred to merely by the word “Gas.” CGA G-1, 5.2.1 4.2.3.2 When acetylene cylinders are moved, they should* not be subjected to abnormal mechanical shocks that might damage the cylinders, the valves, or the fusible pressure relief devices. Care shall be exercised to ensure that acetylene cylinders are not dropped or permitted to strike each other violently. CGA G-1, 5.2.2 4.2.3.3 Acetylene cylinders should* not be dropped while being unloaded or loaded from a truck or dock. [NOTE: Trucks with elevator tailgates provide a very good means of unloading or loading acetylene cylinders safely.] CGA G-1, 5.2.3 4.2.3.4 When transporting acetylene cylinders by crane or derrick, lifting magnets, slings, ropes or chains, or any other device in which the cylinders themselves form a part of the carrier should* never be used for hoisting acetylene cylinders. When transporting acetylene cylinders by crane, a platform, cage or ladle should* be if will protect the cylinders from damage and will keep them from falling out. CGA G-1, 5.2.4 4.2.3.5 A positive method such as chaining should* be used in securing acetylene cylinders that are standing upright. During movement, acetylene cylinders shall not be transported when lying horizontally with the valves unprotected in a position that would allow the valves to collide with stationary objects. CGA G-1, 5.2.4 4.2.3.6 Acetylene cylinders should* never be dragged from place to place. DOE-HDBK-1139/3-2005 21 Sources11 Consolidated Requirements12 CGA G-1, 5.2.5 4.2.3.7 Valves shall always be closed before acetylene cylinders are moved. CGA G-1, 5.2.5 4.2.3.8 Unless acetylene cylinders are to be moved while secured in an upright position to a suitable hand truck, pressure regulators should* be removed and valve protection caps, if provided for in the cylinder design, should* be attached. *The CGA Pamphlet uses the word “should.” Since the DOE incorporates the CGA documents by reference the requirement may be interpreted as mandatory. 5.0 Source Documents ANSI, Z49.1 (1999), “Safety in Welding, Cutting, and Allied Processes”. CGA G-1 (1996), “Compressed Gas Association General Requirements for Compressed Gases”. CGA P-1 (2000), “Compressed Gas Association Requirements for Acetylene”. DOE O 460.1A, “Packaging and Transportation Safety”. DOE O 460.1B, “Packaging and Transportation Safety” [NOTE: This order, issued on 4/4/2003, cancels the DOE O 460.1A]. 29CFR1910.101, “Compressed Gases”. 29CFR1910.102, “Acetylene”. 29CFR1910.253, “Oxygen-Fuel Gas Welding and Cutting”. 29CFR1926.350, “Gas Welding and Cutting”. 40CFR302.4, “Listing of Hazardous Substances for the National Oil and Hazardous Substances Pollution Contingency Plan”. 49CFR171-179, “Hazardous Materials Transportation”. DOE-HDBK-1139/3-2005 22 INTENTIONALLY BLANK DOE-HDBK-1139/3-2005 23 Chapter 5 - Chemical Storage 1.0 Introduction

This chapter identifies and consolidates existing user safety and health requirements found in DOE and Federal chemical-related safety and health regulations and National Standards that address the storage of chemicals (see definition) and chemical products (see definition). It specifically consolidates requirements found in the American National Standards Institute (ANSI) Z49.1, the Compressed Gas Association (CGA) G-1, and CGA P-1, National Fire Protection Association (NFPA) 30, NFPA 45, NFPA 51, NFPA 55, NFPA 430, NFPA 432, the Occupational Safety and Health Administration (OSHA) regulations found at 29CFR1910.6, 29CFR1910.106, 29CFR1910.134, 29CFR1910.253, 29CFR1926.350, and 29CFR1910.1200. It includes requirements that are cited in either DOE O 440.1A or 29CFR1910.6 ("Incorporation by Reference") and technical standards that are made mandatory by their specific reference within a regulation, rule or DOE Order. State and local codes and requirements are NOT included. USDA regulations are NOT addressed since the impact from these is considered to be negligible at DOE facilities. Similarly, EPA pesticide regulations are NOT addressed in this document since most DOE sites do not routinely store pesticides. This chapter is intended to list chemical-related safety and health requirements and to consolidate those that are overlapping and/or duplicative. The list of requirements includes “pointers” to the sources of those requirements. This document does NOT create any new or additional requirements. 2.0 Applicability This chapter applies to all locations that store chemicals or chemical products. [NOTE: Throughout this document, the term “chemicals” is used to indicate chemicals and/or chemical products as described in Section 3, below.] This document does NOT apply to: • chemicals stored in tanks with a greater than 735-pound water capacity; • drums that have a greater than 55 gallon capacity; • chemical distribution systems (see definition); • storage containers attached to a system; • waste chemical storage; • the building or design of chemical storage areas [a design engineer who is acquainted with those requirements should be consulted before a chemical storage facility is built or before an existing facility is converted to chemical storage.] Special laboratory requirements presented in this document apply to laboratories that are constructed and operated in accordance with NFPA 45, "Standard on Fire Protection for Laboratories Using Chemicals." This chapter consolidates existing core safety and health requirements that all sites must follow when engaged in chemical-related activities. The requirements included in this chapter come from sources that have different safety purposes. As a result, some of these requirements may not always be DOE-HDBK-1139/3-2005 24 applicable to the work being performed at an individual site or facility. It is the responsibility of each site or facility to determine the applicability of specific requirements to their work and how they are implemented. The reference sources for the requirements included in this chapter can be used to determine the applicability of those requirements to the work being performed. 3.0 Definitions and Acronyms See Glossary. 4.0 Requirements for Chemical Storage Sources11 Consolidated Requirements12 DOE O 440.1A; 29CFR1910.6

[NOTE: The information that follows is a consolidation of existing Federal safety and health requirements and National Standards that relate to the storage of chemicals. It therefore contains "shall" statements that are taken from, or based on "shall" statements in those existing requirements. While NFPA and CGA requirements that are referenced here are not, in and of themselves mandatory, they are made mandatory by OSHA regulation 29CFR1910.6, which incorporates them by reference. DOE O 440.1A mandates compliance with OSHA regulations found in Title 29 of the Code of Federal Regulations (CFR). NFPA and CGA requirements referenced here are thereby made mandatory for DOE contractors through contracts that include DOE O 440.1A. Please see the Introduction to this section of the DOE Chemical Management Handbook for more information.] 4.1 General NFPA 45, 7.2.3.3 4.1.1 Facilities shall be evaluated to determine chemical storage limits, allowable chemical container storage sizes, and stacking limits. Quantities of chemicals stored shall remain within those limits.18 NFPA 430, 2.1.1; NFPA 430, 2.10.1; NFPA 432, 4.7.1 4.1.2 The identification or design of chemical storage areas (see definition),or maintenance work on chemical storage areas shall be reviewed.19 NFPA 430, 2.6.1 4.1.2.1 New facility design shall take into account the need for containment to protect the environment from oxidizers, fire suppression agents, and decomposition products. NFPA 430, 2.6.2 4.1.2.2 Approval (see definition) of chemical storage areas shall take into consideration the potential for large quantities of smoke and toxic fumes, especially as storage affects 18 Facility chemical quantity limits stem primarily from the local fire and building codes. NFPA 45 may modify these for laboratories, by local ordinances or by other codes that are specific to one particular class of chemicals such as NFPA 30, "Flammable and Combustible Liquids". 19 There are restrictions and requirements for welding and cutting activities at locations where chemicals are used and stored. Consult your local welding and cutting program to determine what these requirements are. DOE-HDBK-1139/3-2005 25 Sources11 Consolidated Requirements12 manual fire fighting operations, building egress, and evacuation of adjacent facilities. NFPA 432, 4.7.2 4.1.2.3 Cutting and welding operations in areas where organic peroxides are stored shall not be performed until all organic peroxide formulations have been removed. ANSI Z 49.1, 10.8.2.1; CGA G-1, 4.2.14; CGA P-1, 3.7.3.2; NFPA 30, 4.7.4; NFPA 51, 2.2.1; NFPA 55, 7.1.3.2; 29CFR1910.253(b)(2) (ii); 29CFR1926.350(a)(11) 4.1.3 Chemical storage areas shall be secured using physical or administrative controls to prevent unauthorized entry. 20 CGA P-1, 4.2.1.5; NFPA 55, 7.6.3.2: NFPA 430, 2.9.2; NFPA 432, 4.6 4.1.4 “No smoking” signs shall be posted at all entrances to areas where oxidizers, organic peroxides, or flammable gases are stored. NFPA 30, 4.10; NFPA 430, 2.9.1 4.1.5 Ignition sources such as open flames, smoking, spark producing equipment, static electricity, and other hot sources shall not be permitted in areas where chemicals are stored unless reviewed and approved.21 NFPA 430, 2.2.3; 29CFR1910.1200(f) 4.1.6 All chemicals shall be properly labeled. CGA P-1, 3.7.2; NFPA 45, 7.2.3.4; NFPA 55, 7.1.5.1.1;

4.1.7 Chemicals shall be stored compatibly and in a way to prevent contact with incompatible materials. This includes preventing liquids from flowing out of a chemical storage area into another area where they may be exposed to incompatible materials. 20It is recommended that a graded approach be used in meeting this requirement. 21 Restrictions and requirements for welding and cutting activities at locations where chemicals are used and stored are based on specific conditions. Consult your local facility welding and cutting program to determine what requirements are applicable to specific activities and conditions at your site. 22This requirement is intended to keep chemicals safe during routine storage and during an upset condition such as a fire. Therefore, chemicals that are only incompatible at elevated temperatures are still considered incompatible during routine storage conditions due to the possibility of fire or other upset condition. This document does not DOE-HDBK-1139/3-2005 26 Sources11 Consolidated Requirements12 NFPA 432, 2.3 4.1.7.1 All construction materials in a chemical storage area shall be compatible with those chemicals being stored. NFPA 430, 2.4.2.1 4.1.7.2 Special care shall be taken to prevent the contamination of chemicals in storage. NFPA 430, 2.4.2.2 4.1.7.3 When flammable and combustible liquids are stored in segregated warehouses (see definition) with oxidizers, they shall be separated from those oxidizers by a distance of 25 ft. with dikes, drains, or sloping floors present to prevent the flammable liquids from encroaching on the separation. NFPA 45, 7.2.3.5; NFPA 45, 10.3.2 4.1.8 Chemicals that might become hazardous upon prolonged storage shall be dated when first opened and evaluated for safety every 6 months thereafter. NFPA 45, 7.2.3.5 4.1.8.1 Chemicals that are found to be unsafe and cannot be made safe shall be disposed of safely and in compliance with applicable requirements. CGA G-1, 4.2.2; CGA G-1, 4.2.6; CGA G-1, 4.2.15; CGA P-1, 4.2.1.3; NFPA 30, 4.3; NFPA 45, 7.2.3.6 NFPA 51, 2.2.2; NFPA 51, 2.3.2; NFPA 55, 6.17; 29CFR1910.106(d)(4) (iv) 4.1.9 Indoor chemical storage areas shall have either natural or mechanical ventilation designed to provide a minimum of six air exchanges per hour and shall discharge the air a minimum of 50 ft. from any air intakes for air handling systems, air compressors, etc. [EXCEPTION: Under NFPA 30, 4.3 and NFPA 45, 7-2.3.6 this requirement does not apply to flammable liquid storage cabinets.] NFPA 55, 3.-1.3.b; 29CFR1910.106(d)(4) (iv) 4.1.9.1 A manual shutoff shall be provided outside the toxic gas (see definition) and flammable/combustible liquids storage areas adjacent to the entry door and shall be labeled “Ventilation System Emergency Shutoff.” NFPA 55, 6.17.9 4.1.9.2 Exhaust ventilation shall not be recirculated within any room or building. intend to direct which compatibility scheme should be used. Each site or facility must determine for itself which compatibility scheme they will use to implement this requirement. DOE-HDBK-1139/3-2005 27 Sources11 Consolidated Requirements12 NFPA 432, 4.9.1 4.1.10 Good housekeeping shall be maintained in areas where chemicals are stored. NFPA 30, 4.4.3.1; NFPA 30, 4.5.1.2; NFPA 30, 5.9.1; 29CFR1910.106(d)(5) (i) 4.1.10.1 Aisles established for the movement or egress of personnel shall be maintained clear of obstructions, including stored chemicals. NFPA 30, 4.7.4; NFPA 430, 2.13.1; NFPA 432, 4.-9.1

4.1.10.2 Accumulation of wastes, debris, weeds, and other combustible materials shall be prohibited. NFPA 430, 2.13.2; NFPA 432, 4.9.2 4.1.10.3 Spilled chemicals and broken containers shall be immediately managed using appropriate procedures. NFPA 430, 2.13.3 4.1.10.4 Each used and empty container shall be stored in a manner appropriate for the chemical that existed in that container until it is disposed of or cleaned; OR stored in a detached or sprinklered area (see definition) until disposed of or cleaned. NFPA 430, 2.13.4 4.1.10.5 Storage operations shall be arranged to prevent the accumulation of fugitive dust from the stored chemical. NFPA 432, 4.9.3 4.1.10.6 Specific disposal procedures shall be developed for all areas where organic peroxides are stored. NFPA 45, 7.2.3.1 4.1.11 Hazardous chemicals stored in the open in laboratory work areas shall be kept to the minimum necessary for the work being done. NFPA 45, 8.1.6.5 4.2 Compressed Gases [NOTE: In a laboratory a compressed gas cylinder shall be considered “in use” if it is: a) connected through a regulator to deliver gas to a laboratory operation; or b) connected to a manifold being used to deliver gas to a laboratory operation; or c) a single cylinder secured alongside the cylinder in (a) above as the reserve cylinder.] CGA P-1, 3.7.1; NFPA 55, 6.13.1 4.2.1 Hazard identification signs shall be placed at all entrances to areas where compressed gas is stored. DOE-HDBK-1139/3-2005 28 Sources11 Consolidated Requirements12 NFPA 55, 6.1.13(A); NFPA 704 4.2.1.1 Hazard ratings shall be assigned in accordance with NFPA 704. NFPA 55, 6.13.2.1 4.2.1.2 Signs shall not be obscured or removed. CGA G-1, 4.2.9; CGA P-1, 4.2.1.5; NFPA 55, 6.13.2.2; NFPA 55, 7.1.1; NFPA 55, 7.6.3.2; 29CFR1910.253(b)(3) (i) 4.2.1.3 Signs shall prohibit smoking or an open flame within 20 ft of where toxic, pyrophoric, oxidizing, or flammable gases are stored. ANSI Z49.1, 10.8.2.1; CGA G-1, 4.2.4; CGA P-1, 3.7.2; CGA P-1, 3.7.3; NFPA 51, 2.2.1; NFPA 55, 7.1.5.4; NFPA 55, 7.1.5.6; NFPA 55, 7.1.5.9; 29CFR1926.350(a)(11) 4.2.2 Compressed gas cylinders shall be stored away from stairways, elevators, exit routes, or gangways, in assigned places where they will not be exposed to physical damage (for example, damage from vehicles, damage from falling ice, etc.). ANSI Z49.1, 10.8.2.1; CGA G-1, 4.2.8; CGA P-1, 3.7.4; NFPA 55, 2.2.1.6; NFPA 55, 7.1.3.4; NFPA 55, 7.2.1.2; 29CFR1910.253(b)(2) (ii) 4.2.3 Compressed gas cylinders shall be stored in an upright position (see definition) with their valve protection caps in place and secured to prevent cylinders from falling over or being knocked over. [EXCEPTION: All requirements cited here indicate that upright storage is not required for lecture bottles or cylinders used in self-contained breathing apparatus.] NFPA 55, 6.6.2 4.2.4 Overhead cover for outdoor storage areas of compressed gases shall be of non-combustible construction, open on three sides and shall not be considered indoor storage. NFPA 55, 7.1.5.3 4.2.4.1 Storage areas shall be kept clear of dry vegetation and combustible materials for a minimum distance of 15 ft in all directions. CGA P-1, 3.7.3.1; CGA G-1, 4.2.13; NFPA 55, 2.1.6.1.b 4.2.4.2 Cylinders stored outdoors shall not be placed in direct contact with the earth or on surfaces where water can accumulate. DOE-HDBK-1139/3-2005 29 Sources11 Consolidated Requirements12 ANSI Z49.1, 10.8.1.8;

CGA G-1, 4.2.3; CGA P-1, 3.7.2; NFPA 51, 2.2.1; NFPA 55, 6.6.1; NFPA 55, 7.1.5.7 4.2.5 Compressed gas cylinders in storage shall not be heated above 125°F 23. ANSI Z49.1, 10.8.2.2; ANSI Z49.1, 10.8.2.3; CGA G-1, 4.2.5; CGA P-1, 4.2.4; CGA P-1, 4.4.4; NFPA 51, 2.2.1; NFPA 51, 2.4.3; NFPA 55, 7.1.5.2; 29CFR1926.350(a)(10; 29CFR1926.350(a)(11; 29CFR1910.253(b)(2) (ii); 29CFR1910.253(b)(4) (iii) 4.2.6 Compressed gases in storage shall be segregated from incompatible materials or combustibles in storage by either a distance of 20 ft. or by a noncombustible partition with a fire resistance rating of ½ hour and extending not less than 18 inches above and to the sides of the stored material. The noncombustible barrier shall be five feet high for those cylinders that are less than three and a half feet tall. [EXCEPTION: Under ANSI Z49.1 and NFPA 55 welding gases located on a weld cart are considered to be "in use" and not in storage. This is also consistent with the NFPA 45 definition of "in use". Under these cited standards, then, this requirement does not apply to oxygen and fuel gases on a weld cart. Similarly, since oxygen and fuel gases on a weld cart are considered to be "in use" under these standards, they also are not required to be segregated from each other.] [NOTE: The intent of these requirements is to discourage the manufacture of unsafe weld carts and to prevent the practice of removing welding gases from carts at the end of every work shift or day, since this additional handling of the gases is considered to be inherently more hazardous than is their temporary storage on weld carts. It should be noted , however, that keeping oxygen and fuel gases on a weld cart for excessively long periods without any actual use would counter the intent of these requirements.] NFPA 55, 2.2.1.5 4.2.6.1 Flammable gas cylinders shall be stored a minimum distance of 20 ft. from storage of flammable and combustible liquids and solids. 29CFR1910.253(b)(3) (i) 4.2.7 The inside storage of more than 2,000 standard cubic ft. (scf) of flammable gas, or more than 300 pounds of liquefied petroleum gas requires a separate room, compartment, or special storage building. 23 This requirement includes the storage of compressed gas cylinders in direct sunlight where the sunlight may cause the cylinder to overheat. DOE-HDBK-1139/3-2005 30 Sources11 Consolidated Requirements12 NFPA 55, Chapter 6 4.2.7.1 Indoor storage in one fire area of multiple groups of cylinders containing flammable gas shall be performed according to specifications in NFPA 55, Chapter 6. NFPA 55, Chapter 6 4.2.8 Indoor storage in one fire area of multiple groups of cylinders containing flammable gas shall be performed according to specifications in NFPA 55, Chapter 6. NFPA 55, 2.2.1.7.b 4.2.8.1 Groups may be separated from each other by masonry walls with a fire resistance rating of 2 hours instead of by a minimum distance. NFPA 55, 2.2.1.8 4.2.8.2 Different flammable gases shall be allowed to be stored together. CGA G-1 4.2.6; NFPA 51, 2.3.1; NFPA 55, 2.2.2.1.a 4.2.9 Flammable gases with a collective volume between 2,501 and 5,000 scf, when stored indoors, shall be stored in rooms or enclosures with a minimum 1-hour fire resistance rating. NFPA 55, 2.2.2.2.1 4.2.9.1 Multiple groups of flammable gas cylinders in one sprinklered fire area shall be stored a minimum of 100 ft. apart. NFPA 51, 2.3.2; NFPA 55, 2.2.3.1

4.2.10 Flammable gases with a collective volume greater than 5,000 scf, when stored indoors, shall be stored in a room or enclosure with a minimum fire resistance of 2 hours. NFPA 51, 2.3.2; NFPA 55, 2.2.3.2 4.2.10.1 Rooms used to store compressed gases shall be sprinklered according to NFPA 13. NFPA 55, 7.9.2.1; NFPA 55, 7.9.6.5; NFPA 55, 7.9.6.6 4.2.11 Indoor compressed gas storage areas that are used to store toxic or highly toxic gases indoors shall be equipped with a continuous monitoring system that would provide warning of toxic gas concentrations that could present a hazard to life. NFPA 55, 7.9.2.2; NFPA 55,7.10.2 4.2.12 Outdoor storage areas of toxic gases shall be located 75 ft from a line of property, public ways, places of assembly. NFPA 55, 7.9 4.2.13 Other requirements for the storage of toxic and highly toxic gases can be found in NFPA 55, 7.9. 29CFR1910.134 4.2.14 Where toxic gases are stored, a minimum of two NIOSH approved self-contained breathing apparatus (SCBAs) shall be kept available at all times for use in upset conditions. They shall be cleaned and disinfected after each use, properly maintained and stored, inspected at least monthly, and checked for proper function before and after each use. DOE-HDBK-1139/3-2005 31 Sources11 Consolidated Requirements12 CGA P-1, 4.5.1.3; CGA P-1, 4.5.1.4 4.2.14.1 NIOSH approved SCBAs shall also be provided where protection is deemed necessary for entry into atmospheres containing asphyxiant or corrosive gases.24 CGA P-1, 4.5.1.4 4.2.14.2 One of the two SCBAs present shall be in the possession of a qualified backup person present at the scene when the SCBAs are being used. 4.3 Flammable and Combustible Liquids NFPA 30, 4.4.3.3; NFPA 30, 4.4.3.4; 29CFR1910.106(d)(4) (v) 4.3.1 Aisles in areas that qualify as indoor liquid storage areas as per NFPA 30, "Flammable and Combustible Liquids Code", shall be 4 ft wide. Aisles in other flammable liquid storage areas shall be 6 ft wide. 29CFR1910.106(d)(5) (vi)(f) 4.3.1.1 Aisles at least 3 ft wide shall be provided where necessary to allow for access to doors, windows, or standpipe connections. NFPA 30, 4.4.3.5; NFPA 30, 4.5.14; NFPA 30, 4.5.2.5 4.3.2 Class I flammable liquids (see definition) shall not be stored in basement areas. Class II and Class IIIA combustible liquids (see definition) shall not be stored in basement areas unless those areas are protected with automatic sprinkler systems. NFPA 30, 4.5.1.2 4.3.3 Class I flammable liquids shall not be stored such that a fire in the liquid storage area would prevent egress from the area. NFPA 30, 4.5.28.(a) 4.3.4 In general purpose warehouses, flammable and combustible liquids shall not be stored in the same pile or on the same rack as ordinary combustibles. NFPA 30, 4.4.3.6; NFPA 30, 4.4.3.7; NFPA 30, 4.5.2.8.(b) 4.3.4.1 Ordinary combustibles, other than those used for packaging flammable liquids, shall be stored a minimum of 8 ft from flammable or combustible liquids. NFPA 30, 4.5.2.8.(a) 4.3.4.2 Where flammable liquids are packaged together with ordinary combustibles, such as in kits, storage shall be considered on the basis of whichever commodity predominates. 24 Any other respirator used must go through a NIOSH approval process for equivalency. This process must be described in the facility’s written respiratory protection program. DOE-HDBK-1139/3-2005 32 Sources11 Consolidated Requirements12

NFPA 30, 4.4.3.7 4.3.5 Storage of empty or idle pallets inside a flammable liquid storage area shall not exceed 2,500 ft.2 and 6 ft. in height. NFPA 30, 4.-4.3.8; 29CFR1910.106(d)(5) (vi)(c) 4.3.6 Containers in piles shall be stacked in such a manner as to provide stability and to prevent excess stress on container walls. NFPA 4.4.3.8; 29CFR1910.106(d)(5) (vi)(d) 4.3.6.1 Portable tanks stored over one tier high shall be nested securely without dunnage. NFPA 30, 4.4.3.8 4.3.6.2 Material handling equipment shall be suitable to handle containers and tanks safely at the upper tier level. NFPA 30, 4.4.4.2; 29CFR1910.106(d)(4) (v) 4.3.7 Containers over 30 gallons in size that contain Class I or Class II liquids shall not be stored over one level high in inside rooms (see definition). NFPA 30, 4.4.3.9; 29CFR1910.106(d)(5) (vi)(e) 4.3.8 No stack of flammable or combustible liquids shall be closer than 3 ft. to the nearest beam, chord, or other construction, and shall be 3 ft. below sprinkler deflectors, discharge orifices of water spray, or other overhead fire protection systems. NFPA 30, 4.9; 29CFR1910.106(d)(7) (i) 4.3.9 Suitable fire control devices shall be available at locations where flammable and combustible liquids are stored. 29CFR1910.106(d)(7) (i)(a); 29CFR1910.106(d)(7) (i)(b) 4.3.10 At least one portable fire extinguisher having a rating of not less than 40-B units shall be located outside but not more than 10 ft. from any door to a flammable and combustible liquids storage room or any area where Class I or Class II liquids are stored. NFPA 30, 4.10.1; 29CFR1910.106(d)(7) (iv) 4.3.11 Water reactive materials (see definition) shall not be stored in the same area with flammable or combustible liquids.25 25 This requirement is intended to protect water reactive chemicals from exposure to water in water based fire suppression systems that may be used where flammable liquids are stored. Spraying water on a water reactive material during an upset condition could increase the severity and danger of the upset condition. While not required, consideration should be given to applying a similar restriction in oxidizer storage areas. See section 4.4.2. DOE-HDBK-1139/3-2005 33 Sources11 Consolidated Requirements12 NFPA 30, 4.5.2.3 4.3.12 Class I and Class II liquids in plastic containers shall only be stored in flammable liquids storage rooms (see definition) or flammable liquid storage cabinets. NFPA 30, 4.5.1.3 4.3.13 Liquids used for building maintenance, painting, or other similar infrequent maintenance purposes shall be permitted to be stored temporarily in closed containers outside of flammable liquids storage cabinets or flammable liquids storage areas, if the amount stored does not exceed a 10-day supply at anticipated use rates. NFPA 45, 2.2.1(a); 29CFR1910.106(e)(2) (ii)(b)(1) 4.3.14 The quantity of flammable and combustible liquids that can be stored outside a flammable liquids storage room or flammable liquids storage cabinet is as follows26: a. 25 gallons of Class IA liquids in containers per fire area (see definition), and b. 120 gallons of Class IB, IC, II, or IIIA liquids in containers per fire area. OR a. 570 L (150 gallons) of Class I liquids in sprinklered laboratory units (see definition), and b. 757 L (200 gallons) of Class I, II, and IIIA liquids in sprinklered laboratory units. [NOTE: Second set of “a.” and “b.” refers to Class C laboratories only. See NFPA 45 for proper quantities for Class A, B and D laboratories.]

NFPA 45, 2.2.1.4 4.3.15 With the exception of Section 4.3.12 and 4.3.13, all Class I, II, and IIIA flammable and combustible liquids not in a flammable liquids storage room shall be stored in flammable liquid storage cabinets when not in use. NFPA 30, 4.3.1 4.3.15.1 The total quantity of liquids shall not exceed 120 gallons per cabinet. NFPA 30, 4.3 4.3.15.2 Flammable liquid storage cabinets shall be FM approved or UL listed or built in accordance with NFPA 30. NFPA 30, 4.3.2 4.3.15.3 Not more than three flammable liquid storage cabinets are allowed in any one fire area, except as follows: [EXCEPTION 1: In an industrial occupancy, 26 Numerous types of storage areas (e.g., cutoff storage rooms, mercantile storage areas, inside storage rooms, etc.) can exist. Storage limits for laboratories have been defined in 4.3.14. There are many other types of storage areas and limits for each of these are not included in this document. A fire protection engineer should be consulted to determine storage limits for these other storage areas. DOE-HDBK-1139/3-2005 34 Sources11 Consolidated Requirements12 additional groups of storage cabinets can be located in any fire area if a minimum100-foot separation is maintained. EXCEPTION 2: In an industrial occupancy that is protected by an automatic fire sprinkler system, the number of cabinets can be increased to 6 in a group. EXCEPTION 3: In a laboratory fire area, the number of flammable liquid storage cabinets is not limited; however, the total quantity of flammable and combustible liquids is limited to the quantities as defined in 4.3.14.4.] NFPA 45, 2.2.1.3 4.3.15.4 The maximum amount of Class I, II, and IIIA flammable and combustible liquids that can be stored in a laboratory fire area is 400 gallons of which the maximum amount of Class I flammable liquids is 300 gallons. NFPA 30, 4.6.4 4.3.16 Sites for outdoor storage lockers (see definition) shall be reviewed to ensure proper placement, separation, etc. NFPA 30, 4.6.4 4.3.16.1 Multiple outdoor storage lockers at a given site shall be separated according to requirements in NFPA 30. NFPA 30, 4.6.4.4.1 4.3.16.2 In outdoor storage lockers, containers in their original shipping packages shall be permitted to be stored either on pallets or in piles, while unpacked containers shall be stored on shelves or on the floor. NFPA 30, 4.6.4.4.2 4.3.16.3 No other flammable or combustible materials shall be stored at designated outdoor storage locker sites. NFPA 30, 4.6.4.4.3; NFPA 704 4.3.16.4 Outdoor storage lockers shall be placarded according to NFPA 704. 4.4 Oxidizers [NOTE: Additional requirements can be found in NFPA 430, "Code for Storage of Solid and Liquid Oxidizers", when quantities exceed 4,000 pounds of Class 1 oxidizer (see definition), 1,000 pounds of Class 2 Oxidizer (see definition), 200 pounds of Class 3 Oxidizer (see definition), or 10 pounds of Class 4 Oxidizer (see definition). Oxidizer classes are defined in NFPA 430".] NFPA 430, 2.2.1 4.4.1 Oxidizer storage areas shall be conspicuously identified with the words “Class (appropriate classification number) Oxidizers.” NFPA 430, 2.2.2 4.4.1.1 Areas used to store oxidizers of different classes shall be marked as containing the most severe hazard. DOE-HDBK-1139/3-2005 35 Sources11 Consolidated Requirements12 NFPA 430, 2.11.6 4.4.2 Water based manual fire fighting equipment shall be used in oxidizer storage areas.27 NFPA 430, 2.11.6.1

4.4.2.1 The placement and use of dry chemical extinguishers containing ammonium compounds (Class ABC) shall be prohibited in oxidizer storage areas where oxidizers that can release chlorine are stored. NFPA 430, 2.11.6.2 4.4.2.2 Halon extinguishers shall not be used in oxidizer storage areas. NFPA 430, 2.12 4.4.3 Combustible construction materials that could come into contact with oxidizers shall be coated with a compatible material to prevent their impregnation with the oxidizers. NFPA 430, 2.13.5 4.4.4 Absorptive packing materials, wooden pallets, etc., that are exposed to water containing oxidizers or that contain water soluble oxidizers, and are exposed to water shall be immediately relocated to a safe outside area and properly disposed of. NFPA 430, 2.8.1 4.4.5 Oxidizers shall not be stored where they can be heated to within 25°F of their decomposition temperature or above 120°F, whichever is lower.28 4.5 Organic Peroxides NFPA 432, 4.1 4.5.1 Chemical storage areas used for the storage of organic peroxides shall be conspicuously identified with the words “Organic Peroxides” and by the class. NFPA 432, 4.1.1 4.5.1.1 Areas used to store organic peroxides of different classes per NFPA 432, shall be marked as containing the most severe hazard. NFPA 432, 4.1.2 4.5.1.2 Packages containing organic peroxide formulations shall be individually marked with chemical name and other pertinent information to allow proper classification. NFPA 432, 4.1.3 4.5.1.3 Packages of organic peroxides that require temperature control shall be marked with the recommended storage range. NFPA 432, 4.11.2 4.5.2 A clear space of at least 2 ft. shall be maintained between organic peroxide storage and uninsulated metal walls. 27Oxidizer storage areas and flammable liquids storage areas require water- based fire suppression systems. While there are no requirements to keep water reactive materials away from oxidizers, when storing oxidizers, consideration should be given to the additional hazard posed by the presence of water reactive materials when water suppression systems are activated. 28 Attention should be used to ensure that oxidizers stored in direct sunlight are not heated above allowed temperatures by radiant heating. DOE-HDBK-1139/3-2005 36 Sources11 Consolidated Requirements12 NFPA 432, 4.11.3.1 4.5.3 Incompatible materials and flammable liquids shall not be stored within 25 ft. of organic peroxide formulations in chemical storage areas. [NOTE: Organic peroxide formulations that are also classified as flammable liquids may be stored with other organic peroxide formulations.] NFPA 432, 4.11.3.2 4.5.3.1 If a 25-foot separation cannot be maintained, then a 1- hour, liquid-tight fire barrier shall be permitted. NFPA 432, 4.11.4 4.5.4 Only closed containers shall be permitted in an organic peroxide storage area. NFPA 432, 4.11.6 4.5.5 Fifty-five-gallon drums of organic peroxide formulations shall not be stacked. NFPA 432, 4.4.1 4.5.6 Storage temperatures in chemical storage areas shall be maintained within the recommended storage temperature range for the materials being stored.29 NFPA 432, 4.4.2 4.5.6.1 High and low temperature switches, as applicable, shall be provided in addition to normal temperature controls. These switches shall actuate an alarm to ensure prompt response. NFPA 432, 4.4.3 4.5.6.2 Heating systems shall use low-pressure steam, hot water, or indirectly heated air; cooling systems shall not use direct expansion of a flammable gas.

NFPA 432, 4.4.4 4.5.6.3 Heating or cooling pipes and other heat transfer devices shall not come into contact with organic peroxide containers to cause their overheating or cooling. NFPA 432, 4.5.2 4.5.7 Refrigerators used for storing organic peroxide formulations shall be Class I, Group D, and Division I (i.e., "explosion- proof", as defined in Article 500 of NFPA 70. NFPA 432, 4.5.3 4.5.8 Unventilated, unrefrigerated storage cabinets used for the storage of organic peroxides shall be considered Class I, Division I as defined in Article 500 of NFPA 70. NFPA 432, 4.5.4 4.5.9 Ventilated storage cabinets shall be considered Class I, Division II as defined in Article 500 of NFPA 70. Ventilation must be a minimum of 1 cubic foot/minute/square foot of floor area. 29 Attention should be used to ensure that organic peroxides stored in direct sunlight are not heated above allowed temperatures by radiant heating. DOE-HDBK-1139/3-2005 37 5.0 Source Documents ANSI Z49.1 (1999), "Safety in Welding, Cutting and Allied Processes". CGA G-1 (1996), "Acetylene" CGA P-1 (2000), "Safe Handling of Compressed Gases in Containers". DOE O 440.1A, "Worker Protection Management For DOE Federal And Contractor Employees". NFPA 30 (2000), "Flammable and Combustible Liquids Code". NFPA 45 (2000), "Standard on Fire Protection for Laboratories Using Chemicals". NFPA 51 (1997), "Standard for the Design and Installation of Oxygen-Fuel Gas Systems". NFPA 55 (2003), "Standard for the Storage, Use, and Handling of Compressed and Liquefied Gases in Portable Cylinders". NFPA 430 (2000), "Code for the Storage of Liquid and Solid Oxidizers". NFPA 432 (2002), “Code for the Storage of Organic Peroxide Formulations”. NFPA 704 (2001), "Identification of the Hazards of Materials for Emergency Response". 29CFR1910.6, "Incorporation by Reference". 29CFR1910.106, "Flammable and Combustible Liquids". 29CFR1910.134, "Respiratory Protection". 29CFR1910.253, "Oxygen-Fuel Gas Welding and Cutting". 29CFR1910.1200, "Hazard Communication". 29CFR1926.350, "Gas Welding and Cutting". DOE-HDBK-1139/3-2005 38 INTENTIONALLY BLANK DOE-HDBK-1139/3-2005 39 Chapter 6 - Hazard Control 1.0 Introduction This chapter identifies and consolidates existing user safety and health requirements found in DOE and Federal chemical-related safety and health regulations and National Standards that address the control of hazards associated with activities involving chemicals (see definition) and chemical products (see definition). State and local codes and requirements are NOT included. This chapter specifically consolidates requirements found in the National Fire Protection Association (NFPA), the American National Standards Institute (ANSI), the Compressed Gas Association (CGA), the Occupational Safety and Health Administration (OSHA), and certain Environmental Protection Agency (EPA) regulations and Department of Energy (DOE) Rules and Orders, including technical standards that are made mandatory by their specific reference within a regulation, rule or DOE Order. This chapter is intended to list chemical-related safety and health requirements and to consolidate those that are overlapping and/or duplicative. The list of requirements includes “pointers” to the sources of those requirements. This document does NOT create any new or additional requirements. 2.0 Applicability

The information presented here applies to all locations that use chemicals or chemical products. [NOTE: Throughout this document, the term “chemicals” is used to indicate chemicals and/or chemical products as described in Section 3, below.] This chapter is intended only to address chemical hazard control requirements applicable to chemical user activities. It consolidates existing, core safety and health requirements that all sites must follow when engaged in chemical-related activities. The requirements included in this chapter come from sources that have different safety purposes. As a result, some of these requirements may not always be applicable to the work being performed at an individual site or facility. It is the responsibility of each user to determine the applicability of specific requirements to their work and how they are implemented. The reference sources for the requirements included in this chapter can be used to determine the applicability of those requirements to the work being performed. 3.0 Definitions and Acronyms See Glossary. 4.0 Requirements for Hazard Control Sources11 Consolidated Requirements12 4.1 General (Applicable to all operations/activities involving chemicals) DOE-HDBK-1139/3-2005 40 Sources11 Consolidated Requirements12 DOE O 440.1A, sec. 4(j) 48CFR970.5204, 2(b)(6)30 4.1.1 A hazard prevention/abatement process shall be implemented to ensure that all identified hazards are managed through final abatement or control. DOE O 440.1A, sec. 4(j)(1) 4.1.1.1 Controls shall be incorporated into facility design and procedures. DOE O 440.1A, sec. 4(j)(2) 4.1.1.2 Abatement actions shall be prioritized based on risks to workers and promptly implemented for existing hazards identified in the workplace. Workers shall be protected immediately from imminent danger conditions. DOE O 440.1A, sec. 4(j)(4); 29CFR1910.120(g)(1); 29CFR1910.134(a); 29CFR1910.1450(i) 4.1.1.3 Hazard controls shall be selected using the following hierarchy: (1) Elimination of the hazard through practices such as chemical substitution or process modification; (2) Engineering controls; (3) Work practices and administrative controls; and (4) Personal protective equipment DOE O 440.1A, sec. (4)(e); 29CFR1910.1200(h)(1- 3); 29CFR1910.132(d) 4.1.1.4 Workers shall be informed of and involved in identifying and controlling workplace hazards, including decisions on selection of PPE. DOE O 440.1A, Attachment 1, sec. 5; DOE O 440.1A, Attachment 2; 29CFR1910.1450(c) and (e) 4.1.2 An industrial hygiene program shall be implemented by professionally- and technically-qualified industrial hygienists to reduce the risk of work-related disease or illness in all chemical operations including laboratories. The program shall specify appropriate process modification (including chemical substitution), engineering, administrative, work practice, and/or personal protective control methods to limit exposures to hazardous materials to acceptable levels. 4.2 Hazardous Operations31 (see definition) DOE O 420.1A, 4.2.1; DOE-STD-1120-98; DOE-STD-3009-94; DOE-STD-3011-94; DOE-STD-3016-99 10CFR830 Subpart B, 204(b)(4); 4.2.1 An appropriate combination of chemical substitution, engineering and administrative controls (including the appropriate application of detection methodologies), safe work practices, and PPE shall be implemented to prevent/mitigate adverse impacts from hazardous chemicals on workers, the public, or environment.

30 This requirement of the DOE Acquisition Regulations (DEAR, ES&H Clause) requires development and implementation of controls as part of an overall documented safety management system. 31 The requirements for hazardous operations are in addition to requirements associated with those activities specified in Section 4.1. DOE-HDBK-1139/3-2005 41 Sources11 Consolidated Requirements12 10CFR850.25(c); 29CFR1910.119(e)(3)(iii); 29CFR1910.120(c)(1); 29CFR1910.120(d) and (g)(1); 29CFR1910.252(a); 40CFR68.67(c)(3); 40CFR1502.14; 40CFR1502.16 DOE O 420.1A, 4.2.1(3); 29CFR1910.119(f); 40CFR68.69(b) 4.2.1.1 Written operating procedures shall be developed that include (1) precautions necessary to prevent worker exposure to chemical hazards, e.g., chemical substitution/process change, engineering controls, administrative controls and PPE); (2) control measures to be taken if physical contact or airborne exposure to chemical hazards can occur; (3) fire safety procedures that govern the use and storage of combustible, flammable and other hazardous materials; (4) measures for controlling hazardous chemical inventory; and (5) any required safety systems and their functions. 29CFR1910.119(j); 40CFR68.73 4.2.1.2 Process safety equipment and engineering controls shall have (1) written procedures on maintaining their integrity; (2) training of personnel involved in process maintenance activities; (3) documented inspection and testing that meets manufacturer’s recommendations and good engineering practices; (4) prompt correction of deficiencies that are outside of acceptable operating limits; 29CFR1910.119(f)(4); 29CFR1910.120(d) and (g)(1); 40CFR68.69(d) 4.2.1.3 Safe work practices shall be implemented such as lockout/tagout; permitted confined space entry; removal of non-essential personnel from hazardous material areas; and site and building access control. 29CFR1910.119(k) 40CFR68.85 4.2.1.4 Hot work operations (e.g., cutting, welding, brazing) conducted on or near hazardous operations shall be in accordance with fire prevention and protection requirements in 29CFR1910.252(a) and shall have a permit that authorizes the work to be performed. DOE-HDBK-1139/3-2005 42 Sources11 Consolidated Requirements12 4.3 Requirements for Laboratory Use of Chemicals 29CFR1910.1450(e)(3) 4.3.1 A chemical hygiene plan shall be prepared for laboratory operations that includes safe operating procedures, hazard control measures, operability requirements for protective equipment, provisions for employee training and medical consultations, designation of individuals responsible for implementing the plan, and provisions for employee protection against extremely hazardous substances. 29CFR1910.1450(e)(3)(viii) 4.3.1.1 Particularly hazardous substances include “select carcinogens,” reproductive toxins, and substances with a degree of acute toxicity. Provisions, where appropriate, shall include: • Establishment of a designated area for storage • Use of containment devices • Procedures for safe removal of contaminated waste • Decontamination procedures NFPA 45, 2.2.1.1-4 4.3.2 Fire Hazard Classification – Laboratory units shall be classified Class A (High Fire Hazard), Class B (Moderate fire Hazard), Class C (Low fire Hazard), or Class D (Minimal Fire Hazard), according to the quantities of flammable and combustible liquids present in the lab (outside of the storage area) as specified in Table 2.2.1(a) and Table 2.2.1(b) in NFPA 45. NFPA 45, 2.2.1.5

4.3.2.1 For the purposes of determining laboratory fire hazard classification and the use of tables 2.2.1(a) and (b),, quantities of liquefied flammable gases shall be treated as if they were Class I flammable liquids (see definition); that is, 4L (1.1gal) of liquefied flammable gas is to be considered equivalent to 4L (1.1 gal) of Class I flammable liquid. NFPA 45, 4.1-4.6 4.3.3 All laboratory units shall be provided with fire protection appropriate to the fire hazard, including: automatic fire extinguishing systems, standpipe and hose systems, portable fire extinguishers, fire alarm systems, fire prevention programs, and emergency plans. DOE-HDBK-1139/3-2005 43 Sources11 Consolidated Requirements12 NFPA 45, 5.1 4.3.4 If a laboratory contains explosion hazards, as defined in sections 2.3.1 and 2.3.2 of NFPA 45, protection shall be provided by one or more of the following: • limiting the amounts of flammable or reactive chemicals or chemicals with unknown characteristics used in or exposed by experiments; • special preventive or protective measures for the reactions, equipment, or materials themselves (e.g., high-speed fire detection with deluge sprinklers, explosion-resistant equipment or enclosures); • remote control equipment; • sufficient deflagration venting in outside walls; and, • conducting experiments in a detached or isolated building, or outdoors. NFPA 45, 5.2 -5.5 4.3.4.1 Other explosion hazard protection may be considered including: • Explosion-resistant construction; • Explosion venting; • Controlled access to laboratory; and, • Regularly scheduled inspection and maintenance NFPA 45, 7.2 4.3.5 Handling of laboratory chemicals NFPA 45, 7.2.1.1 4.3.5.1 Chemicals shall not be brought into a laboratory work area unless design, construction, and fire protection of the facilities are commensurate with the quantities and hazards of the chemicals involved. NFPA 45, 7.2.2.1 4.3.5.2 Receiving, transporting, unpacking, and dispensing of chemicals and other hazardous materials shall be carried out by trained personnel in such locations and in such a manner as to minimize hazards from flammable, reactive, or toxic materials. NFPA 45, 7.2.2.5 4.3.5.3 Class I liquids shall not be stored or transferred from one vessel to another in any access corridor, open plan buildings, or ancillary spaces unprotected from the exit access corridor. NFPA 45, 7.2.2.6 4.3.5.4 Transfer of Class I liquids to smaller containers from bulk stock containers not exceeding 19L (5 gal.) in capacity shall be performed in one of the following locations: • In a laboratory hood; • In an area provided with ventilation adequate to prevent accumulations of flammable vapor/air mixtures from exceeding 25 percent of the lower flammable limit; DOE-HDBK-1139/3-2005 44 Sources11 Consolidated Requirements12 • In a liquid storage area specifically designed and protected for dispensing Class I flammable liquids that meet the requirements of NFPA 30. NFPA 45, 7.2.2.7 4.3.5.5 Transfer of Class I liquids from containers of 19L (5 gal.) or more capacity shall be carried out as follows: • In a separate building; OR • In a liquid storage area specifically designed for dispensing Class I flammable liquids that meet the requirements of NFPA 30.

NFPA 45, 7.2.2.8 4.3.5.6 Class I liquids shall not be transferred between conductive containers of greater than 4L (1.1 gal.) capacity unless the containers are electrically interconnected by direct bonding or indirect bonding through a common grounding system. When dispensing Class I liquids involves nonconductive containers larger than 4L (1.1gal.), which can be difficult to bond or ground, special dispensing procedures commensurate with the electrical characteristics of the liquid shall be developed and implemented. NFPA 45, 7.2.3.2 4.3.5.7 Individual containers of flammable or combustible liquids shall not exceed the capacities listed in NFPA 45, Table 7.2.3.2. NFPA 45, 7.3-5 4.3.5.8 The quantity of flammable solids, solid or liquid oxidizers, or peroxides allowed shall be limited to the minimum quantity necessary to perform the work being done. Handling of materials shall conform to the manufacturers’ recommendations. NFPA 45, 8.1.4-6 4.3.6 Laboratory Compressed Gases – In addition to the requirements in Section 4.3, above, compressed gas cylinders in laboratories must also meet the requirements in sections 4.3.6.1-5 below. NFPA 45, 8.1.4.1 4.3.6.1 Lecture bottle-sized cylinders of the following gases located in laboratory units shall be kept in a continuously mechanically ventilated hood or other continuously mechanically ventilated enclosure: (1) All gases that have an NFPA 45 Health Hazard Ratings of 3 or 4; (2) All gases that have a NFPA 45 Health Hazard Rating of 2 without physiological warning properties; and (3) Pyrophoric gases DOE-HDBK-1139/3-2005 45 Sources11 Consolidated Requirements12 NFPA 45, 8.1.4.2 4.3.6.2 Cylinders of gases that are greater than lecture bottle size and have NFPA 45 Health Hazard Ratings of 3 or 4, and cylinders of gases that have a Health Hazard Rating of 2 without physiological warning properties that are located in laboratory units shall meet both the following conditions: (1) Storage in approved continuously mechanically ventilated gas cabinets; and (2) Compliance with the requirements of Chapter 3, Toxic Gases, of NFPA 55. NFPA 45, 8.1.4.3 4.3.6.3 Cylinders of pyrophoric gases that are greater than lecture bottle size that are located in laboratory units shall be kept in approved continuously mechanically ventilated, sprinklered gas cabinets. NFPA 45, 8.1.5.2.1-2 4.3.6.4 Regulator systems in laboratory operations shall be equipped with two gauges, either on the regulator or remote from the regulator, installed as to show both the cylinder pressure and the outlet pressure. When the source cylinder is outside of the laboratory, a station regulator and gauge shall be installed at the point of use to show the outlet pressure. NFPA 45 8.1.6.3-4 4.3.6.5 Only in use cylinders shall be allowed in the immediate work area. A compressed gas cylinder shall be considered in use when it is: (1) connected through a regulator to deliver gas; or (2) connected to a manifold being used to deliver gas; or (3) a single cylinder secured as a reserve cylinder alongside the cylinder described in (1). NFPA 45, 8.1.6.5 4.3.6.6 The maximum internal volume (water volume) of all cylinders in each of the listed classifications, in use in the laboratory work area, shall comply with the following [based on internal cylinder volume at 21°, 101 kPa (70°F, 1 atm)]: (a) Maximum Quantity of Flammable Gases. (1) For a laboratory work areas of 500 ft² or less, the internal cylinder volume in standard cubic feet equals 6.0.

(2) For a laboratory work area greater than 500 ft² or less, the internal cylinder volume is 0.012 ft³ per ft² lab work area. DOE-HDBK-1139/3-2005 46 Sources11 Consolidated Requirements12 (b) Maximum Quantity of Oxidizing Gases. (1) For a laboratory work area of 500 ft² or less, the internal cylinder volume in standard cubic feet equals 6.0. (2) For a laboratory work area greater than 500 ft ² or less, the internal cylinder volume is 0.012³ ft per ft² lab work area. (c) Maximum Quantity of Liquefied Flammable Gases. (1) For a laboratory work area of 500 ft² or less, the internal cylinder volume in standard cubic feet equals 1.2. (2) For a laboratory work area greater than 500 ft², the internal cylinder volume is 0.0018 ft³ per ft² labor work area. (d) Maximum Quantity of Health Hazard 3 or 4 gases. (1) For a laboratory work area of 500 ft² or less, the internal cylinder volume in standard cubic feet equals 0.3. (2) For a laboratory work area greater than 500 ft ², the internal cylinder volume is 0.0006 ft³ per ft² lab work area. NFPA 45, 9.1.2-9.2.7.2 4.3.7 Laboratory Operations and Apparatus – NFPA 45 contains additional laboratory safety controls covering: • Operations: heating, distillation, other separation procedures, drying, mixing and grinding, and operations involving reactions at temperatures and pressures above and below ambient conditions. • Apparatus: refrigeration and cooling equipment, heating equipment, pressure equipment, and analytical instruments. 4.4 Combustible Liquids NFPA 30, 5.2 4.4.1 Operations involving flammable or combustible liquids shall be located and operated so that they do not constitute a significant fire or explosion hazard to life or property. NFPA 30, 5.9.1; 29CFR1910.106(b)(6); 29CFR1910.106(e)(6)(1) 4.4.2 Precautions shall be taken to prevent the unintentional ignition of flammable vapors. DOE-HDBK-1139/3-2005 47 Sources11 Consolidated Requirements12 NFPA 30, 5.-9.2 4.4.2.1 Smoking shall be permitted only in designated and properly identified areas. NFPA 30, 5.-9.3; 29CFR1910.106(e)(8) 4.4.2.2 Welding, cutting, and similar spark-producing operations shall not be permitted in areas containing flammable or combustible liquids until a written permit authorizing such work has been issued. NFPA 30, 5.9.4; 29CFR1910.106(e)(6)(ii) 4.4.2.3 All equipment (such as tanks, machinery, and piping) where an ignitable mixture could be present shall be bonded or connected to a ground. The bond or ground or both shall be physically applied or shall be inherently present by the nature of the installation. Electrically isolated sections of metallic piping or equipment shall be bonded to the other portions of the system or shall be individually grounded. 29CFR1910.106(d)(2)(iii) 4.4.332 Individual containers of flammable or combustible liquids shall not exceed the capacities listed in 29CFR1910.106, Table H-12. NFPA 30, 4.5.5.2 4.4.4 In an office occupancy, containers of Class I liquids that are outside of an inside liquid storage (see definition) area shall not exceed a capacity of one gallon (3.8 liters). [EXCEPTION: safety cans (see definition) are permitted up to a two-gallon capacity.] NFPA 30, 4.5.5.3 4.4.5 In an office occupancy, not more than ten gallons (37.8 liters) of Class I and Class II liquids (see definition) combined shall be kept in a single fire area (see definition) outside of a storage cabinet or an inside liquid storage area, unless the liquids are in safety cans (see definition).

32 Glass or plastic containers up to one gallon in size may be used for Class IA or IB liquids if either (1) the liquid would be rendered unfit for its intended use by contact with metal, (2) the liquid would corrode a metal container so as to create a leakage hazard, (3) the process would require more than the allowed quantities of liquid of a single assay lot to be used at one time, or (4) the process would require the maintenance of an analytical standard liquid of a quality which is not met by the specified standards of liquids available, and the quantity of the analytical standard liquid required for any one control process exceeds one-sixteenth the capacity of the container allowed under Table 1. DOE-HDBK-1139/3-2005 48 Sources11 Consolidated Requirements12 NFPA 30, 4.-5.5.4 4.4.6 In an office occupancy, not more than 25 gallons (94.6 liters) of Class I and Class II liquids (see definition) combined shall be kept in a single fire area in safety cans outside of a storage cabinet or an inside liquid storage area. NFPA 30, 4.5.5.5 4.4.7 In an office occupancy, not more than 60 gallons (227 liters) of Class III liquids (see definition) shall be stored outside of an inside liquid storage area or storage cabinet. NFPA 30, 5.13.2.1 4.4.8 Wherever flammable or combustible liquids are used, either fire extinguishers or pre-connected hoses shall be provided in accordance with NFPA 30. 29CFR1910.106(a)(18)(iii) 4.4.9 Whenever a combustible liquid is heated for use to within 30°F (16.7°C) of its flash point, it shall be handled in accordance with the requirements for the next lower class of liquids. NFPA 30, 5.13.4.1 4.4.10 An approved (see definition) means for prompt notification of fire or emergency to those within the plant and to the fire department shall be provided. NFPA 30, 5.13.4.2 4.4.11 Those areas, including buildings, where a potential exists for a flammable liquid spill shall be monitored for the presence of those liquids. NFPA 30, 5.13.6.1 4.4.12 All fire protection equipment, and associated alarms, interlocks, and controls, shall be properly maintained, and periodic inspections and tests shall be done in accordance with both standard practice and the equipment manufacturer’s recommendations. NFPA 30, 5.13.6.2; 29CFR1910.106(e)(9)(i) 4.4.13 Maintenance and operating practices shall control leakage and prevent spillage of flammable liquids. 29CFR1910.106(e)(9)(i) 4.4.14 Spills shall be cleaned up promptly. NFPA 30, 5.13.6.3; 29CFR1910.106(e)(9)(iii) 4.4.15 Combustible waste material and residues in operating areas shall be kept to a minimum, shall be stored in covered metal containers, and shall be disposed of daily. DOE-HDBK-1139/3-2005 49 Sources11 Consolidated Requirements12 NFPA 30, 5.13.6.4; 29CFR1910.106(e)(9)(iv) 4.4.16 Ground areas around facilities where liquids are used shall be kept free of weeds, trash, or other unnecessary combustible materials. NFPA 30, 5.13.6.5; 29CFR1910.106(e)(9)(ii) 4.4.17 Aisles established for movement of personnel shall be maintained clear of obstructions. NFPA 30, 5.5.2; 29CFR1910.106(e)(2)(iv)(d) 4.4.18 Flammable liquids or combustible liquids at temperatures at or above their flash points shall be drawn from or transferred into vessels, containers, or portable tanks using one of the following methods: • from original shipping containers with a capacity of five gallons (19 liters) or less; • from safety cans; • through a closed piping system; • from portable tanks or containers by means of a

device that has anti-siphoning protection and that draws through an opening in the top of the tank or container; • by gravity through a listed self-closing valve or self-closing faucet. [NOTE: Class I-A liquids (see definition) shall not be dispensed by gravity from tanks.] 29CFR1910.106(e)(2)(iv)(d) 4.4. 19 Transferring flammable or combustible liquids by means of air pressure on the container or tank shall be prohibited. 29CFR1910.106(d)(4)(v) 4.4.20 Dispensing in inside storage rooms shall be by approved pump or self-closing faucet only. NFPA 30, 5.5.2.1 4.4.21 If hose is used in the transfer operation, it shall be equipped with a self-closing valve without a hold-open latch in addition to the outlet valve. Only listed or approved hose shall be used. NFPA 30, 5.5.2.2 4.4.22 Means shall be proved to minimize generation of static electricity. Such means shall meet the requirements of NFPA 30. 29CFR1910.106(e)(6)(ii) 4.4.23 Class I liquids (see definition) shall not be dispensed into containers unless the nozzle and container are electrically interconnected. DOE-HDBK-1139/3-2005 50 Sources11 Consolidated Requirements12 NFPA 30, 5.5.2.3 4.4.24 If pumps are used to transfer liquids, means shall be provided to stop the transfer in the event of a spill or fire. 29CFR1910.106(e)(2)(iii) 4.4.25 Areas in which flammable or combustible liquids are transferred from one tank or container to another container shall be separated from other operations in the building by adequate distance or by construction having adequate fire resistance. Adequate natural or mechanical ventilation shall be provided. NFPA 30, 4.4.5.1 4.4.26 Dispensing of flammable liquids or dispensing of combustible liquids at temperatures at or above their flash points shall not be permitted in cutoff rooms or attached buildings that exceed 1000 ft2 (93m2) in floor area or in liquid warehouses unless the dispensing area is suitably cut off from the storage areas in accordance with NFPA 30. NFPA 30, 4.5.2.9 4.4.27 Dispensing of flammable liquids or of Class II combustible liquids shall not be permitted in general purpose warehouses unless the dispensing area is suitably cut off from other ordinary combustible or liquid storage areas in accordance with NFPA 30, and otherwise complies with NFPA 30. 29CFR1910.106(e)(2)(iv)(a) 4.4.28 Flammable liquids shall be kept in covered containers when not actually in use. 29CFR1910.106(e)(2)(iv)(b) 4.4.29 Where flammable or combustible liquids are used or handled, except in closed containers, means shall be provided to dispose promptly and safely of leakage and spills. 29CFR1910.106(e)(2)(iv)(c) 4.4.30 Class I liquids shall be used only where there are no open flames or other sources of ignition within the possible path of vapor travel. 4.5 Compressed Gases 29CFR1910.101 4.5.1 Compressed gas cylinders shall be used in accordance with the Compressed Gas Association (CGA). NFPA 55, 4.2; 29CFR1910.253(b)(1)(ii) 4.5.2 Compressed gas cylinders shall be appropriately labeled. Whenever possible, labels shall be located near the shoulder of the cylinder. DOE-HDBK-1139/3-2005 51 Sources11 Consolidated Requirements12 CGA P-1, 3.2.5 4.5.2.1 The color of the cylinder shall not be the only means used to identify the gas it contains. ANSI Z49.1, 10.8.1.4 and 5; CGA G-1, 5.1.3; CGA P-1, 3.2.2; NFPA 55, .7.1.2.2; 29CFR1910.253(b)(5)(ii)(L) 4.5.2.2 Labels or markings placed on compressed gas cylinders by the manufacturer or distributor shall not be defaced or removed.

ANSI Z49.1, 10.8.1.4 4.5.2.3 Cylinders not bearing a legible label or other identification shall not be used and shall be returned to the manufacturer or distributor. NFPA 51, 2.1.3 4.5.2.4 Gas name markings shall not be cut into the metal of the cylinder by the user. CGA P-1, 3.3.3 4.5.3 Compressed gas cylinders shall not be subjected to temperature extremes. ANSI Z-49.1, 10.8.1.8; CGA P-1, 3.3.3; NFPA 55, 7.1.5.5; 29CFR1910.253(b)(2)(i) 4.5.3.1 Compressed gas cylinders shall not be exposed to temperatures exceeding 125°F CGA P-1, 3.3.3; CGA P-1, 4.2.2; CGA G-1, 5.1.6; CGA G-1, 5.3.3.12; NFPA 55, 7.1.5.7; 29CFR1926.350(b)(3) 4.5.3.2 Direct flames or heat shall not be applied to a compressed gas cylinder. CGA P-1, 3.3.6; NFPA 55, 7.1.8 4.5.3.2.1 Cylinders exposed to fire shall not be shipped or used until the manufacturer or supplier requalifies them in accordance with the pressure and vessel code under which they were manufactured. DOE-HDBK-1139/3-2005 52 Sources11 Consolidated Requirements12 ANSI Z49.1 10.8.4.13; 29CFR1910.253(b)(5)(ii)(L); 29CFR1926.350(b)(1) 4.5.3.2.2 Cylinders shall be kept far enough away from operations such as welding to prevent sparks, hot slag, flames, etc., from reaching them. If cylinders cannot be kept a sufficient distance away, then fire-resistant shields shall be used to separate the cylinders from the hot operations. CGA P-1, 3.3.4 4.5.3.3 Cylinders shall not be subjected to artificially low temperatures without the permission of the supplier. Outside storage is not affected by this requirement. CGA P-1, 3.3.8; NFPA 55, 7.1.1.2.1; NFPA 55, 7.1.9.1; 29CFR1926.350(c)(3) 4.5.4 No structurally damaged or defective cylinders shall be used. Damaged or defective cylinders shall be removed from service. ANSI Z49.1, 10.8.1.2; ANSI Z49.1, 10.8.1.3; CGA P-1, 3.6; CGA G-1, 5.1.7; 29CFR1910.253(b)(5)(ii)(M); 29CFR1926(c)(2) 4.5.5 No person other than the cylinder supplier shall mix or refill gases in cylinders. Used, non-refillable containers shall be disposed of according to the manufacturer’s recommendation. 29CFR1926.350(c)(2) 4.5.5.1 No one shall use a cylinder’s contents for purposes other than those intended by the supplier. ANSI Z49.1, 10.8.3.4; CGA P-1, 3.2; CGA G-1, 5.1.6; 29CFR1910.253(b)(5)(ii)(N); 29CFR1910.253(b)(5)(iii)(H) 4.5.6 No one shall tamper with safety devices in cylinders or valves. CGA P-1, 3.2; CGA P-1, 3.3.8; NFPA 55, 7.1.1.2.1; 29CFR1910.253(b)(5)(ii)(R) (1) and (2) 4.5.6.1 No attempt shall be made to maintain or repair cylinder safety devices. Suppliers instructions as to the disposition of the cylinder shall be followed if a cylinder with a faulty valve or safety device is found or if the cylinder is otherwise found to be defective. DOE-HDBK-1139/3-2005 53 Sources11 Consolidated Requirements12 29CFR1910.253(b)(5)(ii)(R) (3) 4.5.6.2 Complete removal of the stem from a diaphragm-type cylinder valve shall be avoided. [NOTE: Stems may be removed before cylinder disposal.] ANSI Z-49.1, 10.8.4.10; CGA G-1, 5.3.3.11; CGA G-1, 4.2.11; 29CFR1910.253(b)(2)(ii); 29CFR1910.253(b)(2)(iii); 29CFR1910.253(b)(5)(ii)(G); 29CFR1910.253(b)(5)(ii)(H); 29CFR1926.350(a)(8) 4.5.7 When compressed gas cylinders are not in use or are empty, their valves shall be closed. ANSI Z-49.1, 10.8.3.6; CGA G-1, 5.1.9; CGA G-1, 5.5.1; CGA P-1, 3.4.1; NFPA 55, 7.1.4.2; 29CFR1910.253(b)(2)(iv); 29CFR1910.253(b)(5)(ii)(A); 29CFR1926.350(a)(1)

4.5.8 Where cylinders are designed to accept valve protection caps, caps shall be in place and hand tight at all times except when connected for use. CGA P-1, 3.4.2; NFPA 55, 7.1.4.3.1 4.5.9 Where valve outlet caps and/or plugs are provided by the manufacturer, the user shall keep the device on the valve outlet at all times except when secured and connected for use. CGA G-1, 5.5.1; CGA P-1, 3.4.3 4.5.9.2 Valve outlet caps and/or plugs shall be in place and tightened before shipment of the cylinder back to the supplier. ANSI Z-49.1, 10.8.3.2; 29CFR1910.253(b)(5)(ii)(C); 29CFR1926.350(a)(5) 4.5.10 Pry bars shall not be used under valves or valve protection caps to pry cylinders loose when frozen or otherwise affixed to the ground. 29CFR1926.350(a)(5) 4.5.10.1 Warm, not boiling water shall be used to thaw cylinders loose. DOE-HDBK-1139/3-2005 54 Sources11 Consolidated Requirements12 ANSI Z49.1, 10.8.3.3; CGA P-1, 3.3.1; CGA G-1 5.1.10; 29CFR1910.253(b)(5)(ii)(K); 29CFR1926, 350(c)(1) 4.5.11 Compressed gas cylinders shall not be used as rollers or supports. 29CFR1926. 350(a)(11) 4.5.12 Compressed fuel gas cylinders shall not be kept in unventilated enclosures such as lockers or cupboards. ANSI Z-49.1, 10.8.4.14; CGA P-1, 3.3.2; CGA G-1, 5.1.8; NFPA 55, 7.1.5.10; 29CFR1910.253(b)(5)(ii)(J); 29CFR1926.350(b)(2) 4.5.13 Compressed gas cylinders shall not be placed where they can inadvertently become part of an electrical circuit. CGA P-1, 3.3.2 4.5.13.1 When used in conjunction with electric welding, compressed gas cylinders shall not be grounded or used for grounding. ANSI Z49.1, 10.8.4.14; 29CFR1926.350(b)(2); 29CFR1910.253(b)(5)(ii)(J) 4.5.13.2 Electrodes shall not be struck against a compressed gas cylinder to strike an arc. ANSI Z49.1, 10.8.2.5; ANSI Z49.1,10.8.4.12; CGA P-1, 3.7.4; NFPA 45, 8.1.5.1; NFPA 55, 7.1.3.4; NFPA 55, 7.2.1.2.2; NFPA 55, 7.3.1.7.1; NFPA 55, 7.3.1.8; 29CFR1926.350(a)(7) and (9); 29CFR1926.350(b)(3) 4.5.14 Compressed gas cylinders shall be secured in an upright position when being used unless specifically designed for a horizontal application. [EXCEPTION: Cylinders containing non-flammable liquefied gases may be used in the inverted position when the liquid phase is used.] DOE-HDBK-1139/3-2005 55 Sources11 Consolidated Requirements12 ANSI Z49.1, 10.3.3; ANSI Z49.1, 10.6.5; CGA G-1, 5.3.3.4; CGA P-1, 3.8.7; 29CFR1910.253(3)(1); 29CFR1926.350(f)(1) 4.5.15 Oxygen and fuel and other compressed gas cylinders, equipment, pipelines or apparatus shall not be used interchangeably with any other gas and each shall be used only for the service for which it was approved. ANSI Z49.1, 10.5.2.1; CGA G-1, 5.3.3.6; CGA P-1, 3.8.4; NFPA 55, 7.3.1.4.1 4.5.16 All connections shall be gas tight and no leaks shall be present in the system. ANSI Z49.1, 10.5.2.1; CGA P-1, 4.2.1.5 4.5.16.1 A flame shall not be used for the detection of leaks in compressed gas systems. Soapy water is one acceptable method. CGA P-1, 3.7.5; CGA P-1, 3.8.2; NFPA 55, 7.3.1.4.2 4.5.17 Backflow protection shall be used when the backflow of gas can result in a hazardous condition. NFPA 55, 7.3.1.2; NPFA 55, 7.5-7.10 4.5.18 Compressed gas systems shall be designed for their intended use and shall be designed by persons competent in such design. . [NOTE: Additional requirements for corrosive, flammable, oxidizing, pyrophoric, toxic/highly toxic, and unstable reactive gases can be found in NFPA 55, 7.5-7.10.]

ANSI Z49.1, 10.8.4.1; CGA G-1, 5.3.1; CGA P-1, 3.8.8; NFPA 45, 8.1.5.2; NFPA 51, 3-1.4; NFPA 51, 3-2.5; NFPA 51, 3-4.5; 29CFR1926.350(d)(3); 29CFR1910.253(b)(5)(iii)(I) 4.5.19 Compressed gases shall never be used from cylinders or high pressure manifolds without reducing the pressure through a suitable regulator unless the equipment used is designed to withstand full cylinder pressure. DOE-HDBK-1139/3-2005 56 Sources11 Consolidated Requirements12 29CFR1910.253(b)(5)(ii)(P) 4.5.19.1 Unless connected to a manifold, oxygen from a cylinder shall not be used without a regulator. ANSI Z49.1, 10.7.1; ANSI Z49.1, 10.7.2; CGA G-1, 5.3.3.4; NFPA 51, 5-6; NFPA 45, 8.1.5.2; 29CFR1910.253(a)(3); 29CFR1910.253(e)(6)(i) 4.5.20 Approved gas regulators and pressure reducing valves shall be used only for the gas and pressures for which they are labeled. 29CFR1926.350(h); 4.5.21 Regulators, including their related gauges, shall be in proper working order while in use. ANSI Z49.1, 10.7.3; 29CFR1910.253(e)(6)(iv) 4.5.21.1 Union nuts and connections shall be inspected before cylinder use to detect faulty seals, which could cause leakage. Faulty nuts and connectors shall be replaced. ANSI Z49.1 10.7.6; CGA G-1, 5.1.5; 29CFR1910.253(e)(6)(ii) 4.5.21.2 A qualified mechanic shall perform repair of regulators or their parts. ANSI Z49.1, 10.7.5; ANSI Z49.1, 10.8.4.11; CGA G-1, 5.3.3.11; CGA P-1, 3.8.6; 29CFR1910.253(b)(5)(iii)(D); 29CFR1926.350(d)(4) 4.5.22 Before a regulator is removed from a cylinder, the cylinder valve shall be closed and the pressure released from the regulator. ANSI Z49.1, 10.7.5; ANSI Z49.1, 10.8.4.4; CGA G-1, 5.3.3.7; CGA P-1, 3.8.1.1; 29CFR1910.253(b)(5)(iii)(J); 29CFR1926.350(d)(2) 4.5.23 Cylinder valves shall always be opened slowly to prevent damage to the regulator. ANSI Z49.1 10.8.4.4; CGA P-1, 3.8.1 4.5.23.1 Personnel shall stand to the side and not in front of the regulator orifice when the cylinder valve is opened. DOE-HDBK-1139/3-2005 57 Sources11 Consolidated Requirements12 ANSI Z49.1, 10.8.4.7 4.5.24 When a high pressure gas (non-liquefied) cylinder is in use, the valve shall be fully opened to prevent leakage around the valve stem. ANSI Z49.1, 10.8.4.6; CGA G-1, 5.3.3.10; CGA P-1, 3.8.1.1; 29CFR1910.253(b)(5)(ii)(E); 29CFR1910.253(b)(5)(iii)(L); 29CFR1926.350(d)(5) 4.5.25 Cylinders not having a fixed hand wheel shall have keys, handles or non-adjustable wrenches on valve stems while cylinders are in service. 29CFR1926.350(d)(2) 4.5.25.1 Manifolded or coupled cylinders shall have at least one such wrench always available. ANSI Z49.1, 10.8.4.5; CGA P-1, 3.8.1.1 ; CGA G-1, 5.3.3.2; 29CFR1910.253(b)(5)(ii)(Q) (1) 4.5.26 Cylinders having hand wheels shall not be opened using wrenches, hammers or other tools. If the valve cannot be opened by hand, then the manufacturer shall be notified and their directions followed. ANSI Z-49.1, 10.8.3.10; CGA G-1, 5.2.5; 29CFR1910.253(b)(5)(ii)(D); 29CFR1926.350(a)(6) 4.5.27 When cylinders are secured in a suitable hand truck, regulators do not have to be removed and valve protection caps need not be in place before cylinders are moved. When cylinders are to be moved with regulators attached, the cylinder valve must be closed. ANSI Z-49.1, 10.8.3.5; CGA P-1, 3.8.1; 29CFR1910.253(b)(5)(ii)(F); 29CFR1926.350(a)(8) 4.5.28 Cylinder valves shall be closed before moving cylinders. ANSI Z-49.1, 10.8.3.7; CGA P-1, 3.5.1; 29CFR1910.253(b)(5)(ii)(C); 29CFR1926.350(a)(5)

4.5.29 Valve protection caps shall not be used for lifting cylinders. ANSI Z-49.1, 10.8.3.8; CGA G-1, 5.2.3; 29CFR1910.253(b)(5)(ii)(A); 29CFR1926.350(a)(2) 4.5.30 When using a crane, derrick, etc. to transport cylinders, a cradle, boat, pallet, slingboard or other suitable platform shall be used. Compressed gas cylinders shall be secured to the lifting device before they are hoisted. DOE-HDBK-1139/3-2005 58 Sources11 Consolidated Requirements12 ANSI Z-49.1, 10.8.3.8; CGA G-1, 5.2.3; CGA P-1, 3.5. 2; 29CFR1910.252(b)(5)(ii)(A); 29CFR1926.350(a)(2) 4.5.30.1 Choker slings, ropes, chains or magnets shall not be used to hoist compressed gas cylinders. ANSI Z49.1, 10.8.3.1; CGA G-1, 5.2.1, 2 and 6; CGA P-1, 3.5; 29CFR1910.253(b)(5)(ii)(B) and (O); 29CFR1910.253(b)(5)(iii)(B); 29CFR1926.350(a)(3) 4.5.31 Compressed gas cylinders shall not be purposely dropped, struck or permitted to strike each other violently. ANSI Z-49.1, 10.8.3.9; CGA G-1, 5.2.5; 29CFR1926.350(a)(4) and (9) 4.5.32 When compressed gas cylinders are transported by motor vehicle, they shall be secured in an upright position. 29CFR1926.350(a)(3) 4.5.33 When large cylinders are moved by hand, they shall be tilted and rolled on their bottom edge. ANSI Z49.1, 10.8.4.3; CGA G-1, 5.3.3.3; 29CFR1910.253(b)(5)(iii)(C); 29CFR1926.350(d)(1) 4.5.34 Before connecting a regulator to an oxygen or fuel cylinder valve, the valve shall be inspected, wiped clean and the valve shall be opened momentarily and then closed immediately. This process is called “cracking”. ANSI Z49.1, 10.8.4.3; CGA P-1, 3.3.9; 29CFR1910.253(b)(5)(iii)(C); 29CFR1926.350(d)(1) 4.5.34.1 The person cracking the valve shall stand to one side and not in front of the gas stream. Compressed gas streams shall not be directed towards any person. ANSI Z49.1, 10.8.4.3; 29CFR1910.253(b)(5)(iii)(D); 29CFR1926.350(d)(1) 4.5.34.2 Fuel cylinder valves shall not be cracked near ignition sources such as flames, welding work, sparks, etc.. DOE-HDBK-1139/3-2005 59 Sources11 Consolidated Requirements12 29CFR1926.350(e)(3) 4.5.34.3 Hose connections shall be kept free of grease and oil. ANSI Z 49.1, 10.6.1; 29CFR1910.253(e)(5)(i) 4.5.35 Hoses for oxy-fuel gas service shall comply with the Rubber Manufacturers Association IP-7 Specification for Rubber Welding Hose. ANSI Z49.1, 10.6.2; 29CFR1926.350(f)(1) 4.5.36 Fuel gas hoses shall be red and oxygen hoses shall be green when they are used for welding and cutting activities. ANSI Z49.1, 10.6.3; 29CFR1910.253(e)(5)(ii); 29CFR1926.350(f)(2) 4.5.37 When parallel lengths of oxygen and fuel gas hoses are taped together such as in a welding operation, not more than 4 inches out of every 12 shall be covered by tape. ANSI Z49.1, 10.6.4; 29CFR1910.253(e)(5)(v); 29CFR1926.350(f)(3) 4.5.38 All hoses used for welding, cutting and other hot work that will be used to carry hazardous gas (for example, oxygen, fuel gases, oxidizers) shall be inspected at the beginning of each working shift that they are to be used and any defective hoses shall be removed from service. [NOTE: Defects in hoses that shall render the hose no longer useable include leaks, burns, and worn places that render the hose unfit for service.] ANSI Z49.1, 10.6.5; 29CFR1910.253(e)(5)(iii) 4.5.39 Hose connections shall comply with the CGA Pamphlet E-1, Regulator Connection Standards. ANSI Z49.1, 10.6.5 4.5.39.1 Hose connections for welding gas lines shall not be compatible with breathing air equipment.

ANSI Z49.1, 10.6.6; 29CFR1910.253(e)(5)(iv) 4.5.39.2 Hose connections shall be able to withstand, without leakage, twice the normal operating pressure and not less than 300 psi. ANSI Z49.1, 10.6.6; 29CFR1910.253(e)(5)(iv) 4.5.39.3 Oil-free air or an oil-free inert gas shall be used to test hose connections. 29CFR1926.350(f)(6) 4.5.39.4 Storage areas for hoses shall be well ventilated. ANSI Z49.1, 10,9.3; ANSI Z49.1, 10.9.4; ANSI Z49.1, 10.9.5; NFPA 51; 29CFR1910.253 4.5.40 Fuel gas and oxygen manifolds capacity limits, locations and design criteria shall be in accordance with NFPA 51 and 29CFR1910.253. DOE-HDBK-1139/3-2005 60 Sources11 Consolidated Requirements12 CGA G-1, 5.1.4; 29CFR1910.253(c)(5)(i) 4.5.41 Fuel gas and oxygen manifolds shall be installed under the supervision of someone familiar with the proper practices. ANSI Z49.1, 10.9.2; 29CFR1910.253(c)(5)(ii) 4.5.42 All manifolds and their parts shall be used only for those gases for which they are approved. ANSI Z49.1, 10.9.1; NFPA 51, 3-2.1; NFPA 51, 3-1.1; 29CFR1910.253(c)(1)(i) 4.5.42.1 Manifolds shall be approved either separately for each of their components or as an assembled unit. 29CFR1926.350(e)(1) 4.5.43 Manifolds shall bear the name of the substance contained inside in letters at least 1 inch high either directly painted upon the manifold or on a sign permanently affixed to the manifold. NFPA 51, 3-3.5 4.5.43.1 Low pressure manifolds shall be marked as such to prevent the attachment of high pressure cylinders. 29CFR1926.350(e)(2) 4.5.44 Fuel gas and oxygen manifolds shall be located in safe, well ventilated, accessible locations and not within enclosed spaces. 29CFR1926.350(e)(3) 4.5.45 Fuel gas and oxygen manifold hose connections shall be such that hoses cannot be interchanged between fuel gas and oxygen manifolds and supply header connections. 29CFR1926.350(e)(3) 4.5.45.1 Adapters shall not be used to permit the interchange of hoses. 29CFR1926.350(e)(4) 4.5.46 When not in use, fuel gas and oxygen manifold and header connections shall be capped. 29CFR1926.350(3)(5) 4.5.47 Nothing shall be placed on top of a fuel gas and oxygen manifold that will damage the manifold or interfere with the quick closing of the valves. NFPA 51, 3-4.1 4.5.48 Portable outlet headers shall not be used indoors except for temporary service as approved by the Occupational Safety and Fire Protection Department. DOE-HDBK-1139/3-2005 61 Sources11 Consolidated Requirements12 ANSI Z-49.1, 10.3.1; CGA P-1, 4.4.1; 29CFR1910.253(b)(5)(i); 29CFR1926.350(h)(i) 4.5.49 Oxygen cylinders, cylinder valves, couplings, regulators, hoses, and other apparatus shall be kept free from oil, grease, dirt and other flammable or explosive substances. These materials shall not be handled with oily hands or gloves. 29CFR1910.253(b)(5)(I); 29CFR1926.350(h)(i) 4.3.49.1 A jet of oxygen gas shall not be directed at an oily surface, greasy clothes, etc. ANSI Z49.1, 10.7.4; 29CFR1910.253(e)(6)(iii) 4.5.50 Gauges used for oxygen service shall be marked “Use No Oil”. ANSI Z49.1, 10.3.2 4.5.51 Oxygen shall not be used as a substitute for compressed air. For example, it shall not be used in pneumatic tools, to blow out pipelines, to dust off clothing or any similar application. ANSI Z49.1, 10.7.5 4.5.52 Oxygen regulators shall be drained of oxygen before they are attached to a cylinder or a manifold or before the cylinder valve is opened. CGA P-1, 4.4.2

4.5.53 Oxygen in work areas shall not be allowed to exceed 23 percent by volume. ANSI Z49.1, 10.8.2.5; 29CFR1910.253(b)(3)(ii); 29CFR1910.253(b)(5)(iii)(A) 4.5.54 Fuel gas cylinders shall be used valve end up. NFPA 55, 7.6.3.1 4.5.55 Where ignition of a flammable gas by static electricity is possible, means shall be provided to prevent static discharge. ANSI Z49.1, 10.8.4.9; CGA G-1, 5.3.3.9; 29CFR1910.253(b)(5)(iii)(E); 29CFR1926.350(d)(2) 4.5.56 Nothing shall be placed on fuel cylinders while in use that could damage safety devices or interfere with the quick closing of the valve. ANSI Z49.1, 10.8.4.8; CGA G-1, 5.3.3.8; 29CFR1910.253(b)(5)(iii)(K); 29CFR1926.350(d)(2) 4.5.57 Quick opening valves on fuel gas cylinders shall be opened between ¾ and 1 ½ turns unless otherwise specified by the manufacturer. ANSI Z49.1, 10.8.4.15 4.5.58 Withdrawal rates from gas cylinders shall not exceed manufacturer’s recommendations. DOE-HDBK-1139/3-2005 62 Sources11 Consolidated Requirements12 ANSI Z49.1, 10.8.5.1; CGA G-1, 5.6.2; 29CFR1926.350(d)(5) 4.5.59 If a leak is found around the valve stem of a fuel gas cylinder, then the packing nuts shall be tightened and the cylinder valve closed. ANSI Z49.1, 10.8.5.2; CGA G-1, 5.6.3; 29CFR1910.253(b)(5)(iii)(F); 29CFR1926.350(d)(5) 4.5.59.1 If these actions do not stop the leak (because the leak is in the valve stem, valve seat, cylinder fuse plug, etc.) then the cylinder shall be moved from the work area to a safe location outdoors and the cylinder shall be properly marked. ANSI Z49.1, 10.8.5.2; CGA G-1, 5.6.3; 29CFR1910.253(b)(5)(iii)(G) 4.5.59.2 Precautionary signs warning of a fire hazard shall be posted where leaking fuel cylinders are located. ANSI Z49.1, 10.8.5.2 4.5.59.3 If a leaking fuel cylinder cannot be moved, then the area shall be evacuated and the fire department shall be summoned for assistance. ANSI Z49.1, 10.8.5.3 4.5.59.4 Small fires at fuel gas cylinders shall be extinguished if possible without endangering personnel by either shutting off the valve or by the use of water. ANSI Z49.1, 10.8.5.3 4.5.59.4.1 Personnel shall evacuate the area and the fire department summoned for assistance if a cylinder fire cannot be easily extinguished. NFPA 51, 4-4.2; NFPA 51, 4-5.2; 29CFR1910.253(d)(5)(ii) 4.5.60 When compressed gas lines are being purged of air, oxygen or combustible gas, then sources of ignition shall not be allowed near uncapped openings. NFPA 51, 1-3.1 4.5.61 The use of liquid acetylene is prohibited. 4.5.62 Details for the following compressed gases can be found in the listed citations: 29CFR1910.102 4.5.62.1 Acetylene 29CFR1910.103 4.5.62.2 Hydrogen 29CFR1910.104 4.5.62.3 Oxygen DOE-HDBK-1139/3-2005 63 Sources11 Consolidated Requirements12 29CFR1910.105 4.5.62.4 Nitrous Oxide 4.6 Specific Chemicals – In addition to the chemical safety controls identified in sections 4.1 through 4.5 of this chapter, there are control requirements for many specific chemicals such as those listed in sections 4.6.1 through 4.6.31 below . Details can be found in the specific citations. 29CFR1910.1014 4.6.1 2-Acetylaminofluorene 29CFR1910.1045 4.6.2 Acrylonitrile 29CFR1910.1011 4.6.3 4-Aminodiphenyl 29CFR1910.1018 4.6.4 Arsenic, inorganic 29CFR1910.1001 4.6.5 Asbestos 29CFR1910.1028 4.6.6 Benzene 29CFR1910.1010 4.6.7 Benzidine 10CFR850 4.6.8 Beryllium 29CFR1910.1051 4.6.9 1,3-Butadiene 29CFR1910.1027 4.6.10 Cadmium

29CFR1910.1008 4.6.11 bis-Chloromethyl ether 29CFR1910.1044 4.6.12 1,2-dibromo-3-chloropropane 29CFR1910.1007 4.6.13 3,3’-Dichlorobenzidine (and its salts) 29CFR1910.1015 4.6.14 4-Dimethylaminoazobenzene 29CFR1910.1012 4.6.15 Ethyleneimine 29CFR1910.1047 4.6.16 Ethylene oxide 29CFR1910.1048 4.6.17 Formaldehyde 29CFR1910.1025 4.6.18 Lead NFPA 484 4.6.19 Lithium NFPA 484 4.6.20 Magnesium solids and powders 29CFR1910.1006 4.6.21 Methyl chloromethyl ether 29CFR1910.1052 4.6.22 Methylene chloride DOE-HDBK-1139/3-2005 64 Sources11 Consolidated Requirements12 29CFR1910.1050 4.6.23 Methylenedianiline 29CFR191 0.1004 4.6.24 alpha-Naphthylamine 29CFR1910.1009 4.6.25 beta-Naphthylamine 29CFR1910.1003 4.6.26 4-Nitrobiphenyl 29CFR1910.1016 4.6.27 N-Nitrosodimethylamine 29CFR1910.1013 4.6.28 beta-Propiolactone NFPA 484 4.6.29 Titanium 29CFR1910.1017 4.6.30 Vinyl chloride NFPA 484 4.6.31 Zirconium 5.0 Source Documents ANSI Z49.1 (1999), "Safety in Welding, Cutting, and Allied processes”. CGA P-1 (2000), "Safe Handling of Compressed Gases in Containers”. DOE O 420.1A, “Facility Safety”. DOE O 440.1A, “Worker Protection Management”. DOE-STD-1120-98, “Integration of Environment, Safety, and Health into Facility Disposition Activities”. DOE-STD-3009-94, “Preparation Guide for U.S. DOE Nonreactor Nuclear Facility Safety Analysis Reports”. DOE-STD-3011-94, “Guidance for Preparation of DOE O 5480.22 (TSR) and DOE O 5480.23 (SAR) Implementation Plans”. DOE-STD-3016-99, “Limited Standard; Hazard Analysis Reports for Nuclear Explosive Operations”. NFPA 30 (2000), “Flammable and Combustible Liquids Code”. NFPA 45 (2000), “Standard on Fire Protection for Laboratories Using Chemicals”. NFPA 55 (2003), “Storage, Use, and Handling of Compressed Gases and Cryogenic Fluids in Portable and Stationary Containers, Cylinders, and Tanks”. NFPA 471 (2002), “Recommended Practice for Responding to Hazardous Materials”. NFPA 472 (2002), “Standard on Professional Competence of Responders to Hazardous Materials Incidents”. NFPA 484 (2002), “Standard for Combustible Metals, Metal Powders, and Metal Dusts”. 10CFR830, “Nuclear Safety Management,” Subpart B, “Safety Basis Requirements”. DOE-HDBK-1139/3-2005 65 10CFR850, “Chronic Beryllium Disease Prevention Program”. 10CFR1021, “National Environmental Policy Act Implementing Procedures”. 29CFR1910.101, “Compressed Gases (general requirements)”. 29CFR1910.102, “Acetylene”. 29CFR1910.103, “Hydrogen”. 29CFR1910.104, “Oxygen”. 29CFR1910.105, “Nitrous oxide”. 29CFR1910.119, “Process Safety Management of Highly Hazardous Chemicals”. 29CFR1910.120, “Hazardous Waste Operations and Emergency Response”. 29CFR1910.132, “Personal Protective Equipment”. 29CFR1910.134, “Respiratory Protection”. 29CFR1910.253, “Oxygen-fuel Gas Welding and Cutting”. 29CFR1910.1001, “Asbestos”. 29CFR1910.1003, “13 Carcinogens (4-Nitrobiphenyl, etc.)”. 29CFR1910.1004, “alpha-Naphthylamine”. 29CFR1910.1006, “Methyl chloromethyl ether”. 29CFR1910.1007, “3,3’-Dichlorobenzidine (and its salts)”. 29CFR1910.1008, “bis-Chloromethyl ether”. 29CFR1910.1009, “beta-Naphthylamine”. 29CFR1910.1010, “Benzidine”. 29CFR1910.1011, “4-Aminodiphenyl”. 29CFR1910.1012, “Ethyleneimine”. 29CFR1910.1013, “beta-Propiolactone”. 29CFR1910.1014, “2-Acetylaminofluorene”. 29CFR1910.1015, “4-Dimethylaminoazobenzene”. 29CFR1910.1016, “N-Nitrosodimethylamine”. 29CFR1910.1017, “Vinyl Chloride”. 29CFR1910.1018, “Inorganic Arsenic”. 29CFR1910.1025, “Lead”. 29CFR1910.1027, “Cadmium”. 29CFR1910.1028, “Benzene”. 29CFR1910.1044, “1,2-dibromo-3-chloropropane”. 29CFR1910.1045, “Acrylonitrile”. 29CFR1910.1047, “Ethylene Oxide”. 29CFR1910.1048, “Formaldehyde”. 29CFR1910.1050, “Methylenedianiline”. 29CFR1910.1051, “1,3-Butadiene”. 29CFR1910.1052, “Methylene Chloride”. 29CFR1910.1200, “Hazard Communication”. 29CFR1910.1450, “Occupational Exposure to Hazardous Chemicals in Laboratories”. 29CFR1926.21, “Safety Training and Education”. 40CFR68, “Chemical Accident Prevention Provisions”. 48CFR970, “DOE Management and Operating Contracts“.

DOE-HDBK-1139/3-2005 66 INTENTIONALLY BLANK DOE-HDBK-1139/3-2005 67 Chapter 7 - Pollution Prevention and Waste Minimization 1.0 Introduction This chapter identifies and consolidates existing user safety and health requirements found in DOE and Federal chemical-related safety and health regulations and National Standards that address pollution prevention (P2) (see definition) and waste minimization for chemicals (see definition) and chemical products (see definition). This chapter specifically consolidates requirements found in 42 USC, 40CFR; the “Greening the Government” Executive Orders 13101, 13148; DOE O 450.1; DOE Acquisition Letter AL-2002-05; and Secretary of Energy Memorandum November 12, 1999, and includes technical standards that are made mandatory by their specific reference within a regulation, rule or DOE Order. This chapter is intended to list chemical-related safety and health requirements and to consolidate those that are overlapping and/or duplicative. The list of requirements includes “pointers” to the sources of those requirements. Requirements for pollution prevention generally involve the integration of P2 into planning, execution, and evaluation of site activities. Chemical users’ participation in pollution prevention arises from their use of chemicals, and from the site’s procurement, distribution, storage and disposal of chemicals. Safety and health program and environmental pollution prevention program protections are usually mutually beneficial, and their requirements frequently mutually inclusive. Consolidated chemical-related safety and health requirements here provide a context for the need for the chemical user to incorporate pollution prevention into every phase of work, such as planning, acquisition, operations, waste management/disposal, and continuous improvement. This chapter does not contain requirements for implementation of Environmental Protection Agency (EPA) reporting requirements or for environmental regulatory compliance. This document does NOT create any new or additional requirements. 2.0 Applicability The information presented here applies to all locations that use chemicals, chemical products or services that involve the use of chemicals or chemical products. [NOTE: Throughout this document, the term “chemicals” is used to indicate chemicals and/or chemical products as described in section 3, below.] This chapter is intended only to address chemical health and safety requirements applicable to chemical user activities. It consolidates existing, core safety and health requirements that all sites must follow when engaged in chemical-related activities. The requirements included in this chapter come from sources that have different safety purposes. As a result, some of these requirements may not always be applicable to the work being performed at an individual site or facility. It is the responsibility of each user to determine the applicability of specific requirements to their work and how they are implemented. The reference sources for the requirements included in this chapter can be used to determine the applicability of those requirements to the work being performed. DOE-HDBK-1139/3-2005 68 3.0 Definitions and Acronyms See Glossary. 4.0 Requirements for Pollution Prevention and Waste Minimization Sources11 Consolidated Requirements12 4.1 Pollution Prevention Policy DOE O 450.1 sec. 4(a)(1), CRD sec. 1(a)

4.1.1 Pollution prevention must be integrated into the planning, execution and evaluation of all site activities. EO 13148, sec. 303; 42 USC 13101 4.1.2 Federal agencies shall preferentially use pollution prevention projects and activities to correct and prevent noncompliance with environmental regulatory requirements. 4.2 Pollution Prevention Programs DOE O 450.1 CRD sec. 9; EO 13148, sec.304 DOE and its contractors shall develop and implement a pollution prevention program at DOE facilities that compares the life-cycle costs of treatment and /or disposal of waste and pollutant streams to the life-cycle costs of alternatives that eliminate or reduce toxic chemicals or pollutants at the source. HSWA sec. 3005(h)(i); 40CFR264.73(b)(9); 40CFR262, 264-265; 40CFR270; 42USC sec. 6922(b) and 6925 (h) 4.2.1 A chemical user who generates hazardous waste must have a program in place to reduce the volume or quantity and toxicity of such waste to the degree determined by the generator to be economically practicable.33 DOE O 450.1, sec. 4.1.(1)(b), CRD sec.1(a) and 3 4.2.2 All DOE elements (see definition) must ensure that sites’ Integrated Safety Management System (ISMS (see definition) includes an Environmental Management System (EMS, see definition) that provides for the systematic planning, integrated execution and evaluation of programs for pollution prevention. 33 This is an implied or indirect requirement to have a waste and toxic