DOE-HDBK-1139-2008, Chemical Management (Part 3 of 3)

TS NOT MEASUREMENT SENSITIVE DOE-HDBK-1139/3-2008 July 2008 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-1139/3-2008 ii This document is available on the Department of Energy Technical Standards Program Web Page at http://www.hss.energy.gov/nuclearsafety/techstds/ DOE-HDBK-1139/3-2008 iii 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 throughout 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, between 50 and 70 percent 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 would be useful to chemical users throughout the Complex and should continue.

In support of the above mandate to assist the sites with a requirements roadmap, the CSTC CUSHR Team developed a series of activity-based chapters that consolidate the safety and health requirements that govern DOE chemical-related work activities. The ten chapters of this document coordinate with the subjects covered in other volumes of the DOE Chemical Management 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 eliminates DOE-HDBK-1139/3-2008 iv the confusion of overlapping and/or duplicative chemical-related safety and health requirements. It serves 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 10 CFR 851, Worker Safety and Health Program, or in OSHA standard 29 Code of Federal Regulations (CFR) 1910.6, 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 because 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. This handbook does not address design requirements and construction aspects of facilities, which can be found elsewhere (for example, DOE O 420.1B, DOE-STD-1066, NFPA 5000). Appendix B is added in this revision to demonstrate how local fire code regulations can have an impact on chemical safety and lifecycle management, for instance, through imposition of facility inventory limits on the storage and use of various hazard classes of chemicals. In the electronic 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. Because 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 front pages of those organizations’ Web sites. 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 have been collected from many sources with differing safety purposes. As a result, some of these requirements may not always apply to the work being performed at a DOE site or facility. It is the user’s responsibility to determine which of these requirements apply to his or her work and how the requirements are to be 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, the user can use the reference sources to research the original requirement. To ensure that the most current document is used, the user should contact the subject matter expert (e.g., fire protection engineer, industrial safety engineer, industrial hygienist, environmental engineer) as applicable, depending on site contractual requirements. DOE-HDBK-1139/3-2008 v Table of Contents Foreword......................................................................................................................................................iii Acknowledgments........................................................................................................................................vi Acronyms and Abbreviations ...................................................................................................................xxii Chapter 1 – Hazard Analysis ........................................................................................................................ 1 Chapter 2 – Acquisition ................................................................................................................................ 6 Chapter 3 – Chemical Inventory and Tracking........................................................................................... 10 Chapter 4 – On-Site Chemical Transportation............................................................................................ 16 Chapter 5 – Chemical Storage .................................................................................................................... 21 Chapter 6 – Hazard Control ........................................................................................................................ 34 Chapter 7 – Pollution Prevention and Waste Minimization........................ Error! Bookmark not defined. Chapter 8 – Chemical Emergency Management......................................................................................... 65 Chapter 9 – Chemical Disposition .............................................................................................................. 83 Chapter 10 – Training ............................................................................................................................... 110 Complete List of Sources.......................................................................................................................... 120 Appendix A: Chapter Overviews.............................................................................................................A-1 Appendix B: Building and Fire Code Overview...................................................................................... B-1

DOE-HDBK-1139/3-2008 vi ACKNOWLEDGMENTS This DOE Handbook was prepared under the sponsorship of the 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 Dave Quigley, BWXT Y-12 and co-chaired by Mr. James Morgan, Washington 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, DOE-RL 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 many individuals who have commented 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 Bill Von Holle DNFSB 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-1139/3-2008 vii ACKNOWLEDGMENTS TO REVISION 1 Revision 1 of this DOE Handbook was prepared under the sponsorship of the CSTC. It was updated by the CSTC’s Document Maintenance team consisting of representatives from several sites and DOE Headquarters. The preparers would like to gratefully acknowledge the following team members who aided in revising this document: Lydia Boada-Clista DOE-Ohio Field Office Wayne Davis WSMS Dave Freshwater NNSA/NA41 Murty Kuntamukkula WSRC Dan Marsick DOE/HS-11 Elaine Merchant DOE/HS-32 James Morgan WSRC Dave Quigley (Chairman) BWXT Y-12 Fred Simmons WSRC Gary Swisstack WSRC DOE-HDBK-1139/3-2008 viii 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. Approved: Acceptable to the authorities having jurisdiction. Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) Hazardous Substance: A substance on the list defined in section 101(14) of the CERCLA (42 USC § 9601-9675). Certain Categories of Property (that require special handling): Specific types of hazardous property, the disposition of which is described in 41 CFR 109-42.11 and 41 CFR 101-42.1102, 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) of items requiring demilitarization (see definition), etc.

Chemical: Any element, compound, or mixture of elements 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 a Material Safety Data Sheet (MSDS) and is not an “Article,” as defined in 29 CFR 1910.1200. 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 MSDSs associated with them and include materials such as paints, lubricants, cleaning agents, and fuels. 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, only the inside of the cabinet is the storage area, not the entire work area. Example 2: Areas used to store low- hazard chemicals 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: The task of monitoring changes to the chemical inventory data 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. Class IC Flammable Liquids: Liquids having a flash point at or above 73°F and below 100°F. DOE-HDBK-1139/3-2008 ix 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 does not spontaneously combust when it comes into contact with combustible materials, but slightly increases 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 causes a moderate increase in the rate at which a combustible burns. Class 3 Oxidizer: An oxidizer that undergoes a vigorous self-sustained decomposition when exposed to contamination or heat or that causes a significant increase in the rate at which combustibles burn. Class 4 Oxidizer: An oxidizer that explosively decomposes upon exposure to heat, shock, or contaminants. Clean-Up Operations: An operation in which 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. Code of Record: The collection of codes and standards used in the approved design of a facility, based upon which the facility is constructed.

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 (15 CFR 774) 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 form 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. Confined Space: Any space not intended for continuous human occupancy and having a limited means of egress that is subject to the accumulation of toxic or flammable contaminants or an oxygen-deficient atmosphere. Confined or enclosed spaces include, but are not limited to, storage tanks, process vessels, 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; and precursors for toxic chemical agents. DOE-HDBK-1139/3-2008 x 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 Substance: (a) Any narcotic, depressant, stimulant, or hallucinogenic drug, or any other drug, other substance, or immediate precursor included in Schedules I, II, III, IV, or V of section 202 of the Controlled Substance Act (Title 21 U.S. Code (USC) Section 812) except exempt chemical preparations and mixtures, and excluded substances listed in 21 CFR 1308; (b) Any other drug or substance that the U.S. Attorney General determines to be subject to control pursuant to Subchapter I of the Controlled Substance Act (21 USC 801 et seq.); or (c) Any other drug or substance that by international treaty, convention, or protocol is to be controlled by the United States. Cryogenic Liquids: Gases that are handled in liquid form at relatively low pressures and extremely low temperatures, usually below –130°F (-90ºC). Dangerous Property: Material that exists in a condition that poses a hazard to public health or safety, thus requiring 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 U.S. 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 Federally-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 (DPMO): Also designated as the DOE National Utilization Officer, who provides approval for user access to the Federal Disposal System (FEDS) (see definition). Dual-Use List2: A list of nuclear-related material, equipment, software, and related technology that has valid uses in both commercial and military applications, developed by the Nuclear Suppliers Group (see 2 The Dual-Use List includes several metals (e.g., beryllium, hafnium, and zirconium) and their compounds and alloys; tritium and its compounds; helium-3, radium-226; chlorine trifluoride; and certain high explosives and their mixtures. DOE-HDBK-1139/3-2008 xi definition) and described in the International Atomic Energy Agency (IAEA) Information Circular (INFCIRC) 254, Part 2 (as amended). Energy Asset Disposal System (EADS): a module within the 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 41 CFR 109-43.304-1.50]. Environmental Management System: “Environmental Management System” means a set of processes and practices that enable an organization to increase its operating efficiency, continually improve overall environmental performance and better manage and reduce its environmental impacts, including those environmental aspects related to energy and transportation functions. EMS implementation reflects accepted quality management principles based on the “Plan, Do, Check, Act,” model found in the ISO 14001:2004(E) International Standard and using a standard process to identify and prioritize current activities, establish goals, implement plans to meet the goals, evaluate progress, and make improvements to ensure continual improvement. 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, Revision 1, Part 1, [as amended]). 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 Property Management Regulations (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 (i.e., 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 parts per million (ppm) (see definition) of Polychlorinated Biphenyls (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, NRC, or which is authorized by DOE. Export-Controlled Property is 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 DOE-HDBK-1139/3-2008 xii determined by the holding agency (see definition) to endanger public health or safety or the environment, if not rendered harmless before release to other agencies or to the general public. Extremely Hazardous Substance: A substance listed in Appendices A and B of 40 CFR 355. Federal Disposal System (FEDS): A real-time, online computer database managed by the General Services Administration (GSA) since 1992 for recording, tracking, and controlling the nationwide inventory of excess and surplus personal property inventory (e.g., equipment and commodities, including chemicals) of the Federal government. GSA’s web-based platform, GSAXcess (http://gsaxcess.gov), is the customer interface to the FEDS. It can be used to access all customer functions of FEDS such as reporting, searching, and selecting inventories of Federal excess, surplus, and exchange or sale 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 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 29 CFR 1910.106 (d)(4) for the storage of flammable and combustible liquids. Flammability Rating of “0” or “1”: Liquids, solids, or semi-solids having a flash point above 200°F or those materials that will not burn when exposed to a temperature of 1500°F for 5 minutes. Friable Asbestos Materials: Materials that contain more than 1 percent asbestos by weight and that can, by hand pressure, be crumbled, pulverized, or reduced to powder, thus allowing for the potential release of asbestos fibers into the air. Foreseeable Emergency: Any potential occurrence such as, but not limited to, equipment failure, container rupture, or control equipment failure, that could result in an uncontrolled release of a hazardous chemical into the workplace. Hazard: Potential for radiation, chemical, energy source or other material to cause human illness or injury or possibly environmental harm. 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 health hazard; a substance that possesses potentially hazardous properties (including, but not limited to, flammability, toxicity, corrosivity, reactivity). DOE-HDBK-1139/3-2008 xiii 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 (4) 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) a flash point below 200°F (93.3°C), closed cup, or is subject to spontaneous heating; b) 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

that have one or more of the following characteristics: (1) causes 50 percent fatalities to test animals below 500 mg/kg of 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 1,000 ppm for gases and vapors, below 500 mg/mm3 for fumes, or 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 photosensitizers; d) radioactive to the extent that it requires special handling; e) a recognized carcinogen according to OSHA regulations at 29 CFR 1910; or f) special characteristics that, 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: The person responsible for directing and coordinating all hazardous materials operations assigned by the IC. Hazardous Materials Regulations (HMR): Department of Transportation (DOT) 49 CFR parts 171 through 180. Hazardous Materials Specialists: Individuals who respond with, and provide support to, hazardous materials technicians. Their duties parallel those of the hazardous materials technician; however, specialist’s 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 regarding 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 or patch leaks or otherwise stop the release of a hazardous substance. 3 Also see the List of Hazardous Substances and Reportable Quantities, which is contained in 40 CFR 302.4, Designation of hazardous substances. DOE-HDBK-1139/3-2008 xiv 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: • 29 CFR 1910.119, Process safety management of highly hazardous chemicals or 40 CFR 68.67 Chemical accident prevention provisions – Process hazards analysis; • hazard category 1, 2, or 3 nuclear operations, as defined in 10 CFR 830, Nuclear Safety Management; • operations involving beryllium, as defined by 10 CFR 850, Chronic beryllium disease prevention program; • facilities with “significant” fire hazards as defined by DOE O 420.1B, Facility Safety; • hazardous waste operations as defined in 29 CFR 1910.120, Hazardous waste operations and emergency response; and • activities subject to National Environmental Policy Act (NEPA) environmental assessment or environmental impact statement as defined in 10 CFR 1021.400.

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 HMTA (49 USC 5101), RCRA (42 USC 6901-6981), or TSCA (15 USC 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 hazards to human health or the environment when improperly used, treated, stored, transported, disposed of, or managed. Hazardous (Personal) Property is a category under High-Risk (Personal) Property (see definition). Hazardous Substance: For the purposes of this document, as defined in 29 CFR 1910.120: A) Any substance defined under section 101(14) of the 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 substance listed by the U.S. Department of Transportation as hazardous materials under 49 CFR 172.101 and appendices; and D) Hazardous waste as herein defined. Hazardous waste means — (A) A waste or combination of wastes as defined in 40 CFR 261.3, or (B) Those substances defined as hazardous wastes in 49 CFR 171.8. . Hazardous Waste4: those materials or substances, the handling and disposal of which are governed by 40 CFR 261, 29 CFR 1910.120, and 29 CFR 1926.65. 4 The definition for hazardous waste, as given in 41 CFR 101-42.001, includes the following caveats: DOE-HDBK-1139/3-2008 xv Highly Protected Risk: Per DOE O 420.1B, the design and construction of a DOE facility to Highly Protected Risk level incorporates a level of fire protection design, systems, and management controls to fulfill requirements for the best-protected class of industrial risks, similar to the best protected class of an industrial building in private industry that qualifies for preferred insurance premium status. 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 general possession of, the chemicals involved. Incident Commander: The person who 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 that 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, instruction, or caution to be placed directly on the primary hazardous material container. Laboratory units: For a complete overview of laboratory units and their definitions, see NFPA 45, Fire Protection for Laboratories Using Chemicals. LC50: The concentration of a vapor or gas that will kill 50 percent of a test population. Exposure periods are typically for 1 hour unless otherwise stated. (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 40 CFR 261.2, 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 40 CFR 261, Subpart D. 5 Excess chemicals identified as high-risk personal property are most likely to belong to category (5), (2), or (3). DOE-HDBK-1139/3-2008 xvi 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, that is required on the outer packaging of hazardous materials. MSDS: Material Safety Data Sheet. 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 or not the material is hazardous. Munitions List7: 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) (22 CFR 121), 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 1,000 ppm but less than or equal to 3,000 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 (see definition) for acute inhalation toxicity is less than or equal to 1,000 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). Non-Appropriated Fund Property: Property (i.e., chemicals) procured without the use of Federal government funds. Nonfriable Asbestos Materials: Materials containing asbestos that 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. 6 Low-Hazard Chemical: This definition makes reference to the hazard identification numbers in NFPA 704, 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 the appropriate ratings for chemicals that have not been rated. Criteria for these ratings are well defined in NFPA 704. The 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 do 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 The U.S. Munitions List includes military explosives, propellants, and toxicological agents. DOE-HDBK-1139/3-2008 xvii 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 Substance (ODS): “Ozone-depleting substances” means any substance designated as a Class I or Class II substance by the EPA in 40 CFR Part 82. ODS, Class I Substance: Any substance designated as Class I by EPA pursuant to 42 USC 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 USC 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 onsite, DOT Hazardous Materials Transportation Regulations must be adhered to.] Operational Emergencies: 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, or 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: According to 29 CFR 1910.1200, a chemical other than a blasting agent or explosive as defined in 29 CFR 1910.109(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 or Polychlorinated biphenyls: A class of chlorinated aromatic compounds that is hazardous to human health and the environment. [NOTE: In 41 CFR 101-42.1102-2, the same acronym “PCBs” is used to mean substances containing polychlorinated biphenyls at a concentration of 500 ppm or greater.]. PCB Items: Materials containing 50 through 499 ppm PCB. 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 USC 2014), as amended; and petroleum in the Strategic Petroleum Reserve and the Naval Petroleum Reserves. For purposes of this document, personal property means chemicals or chemical products. Pollution Prevention (P2): “Pollution prevention” means “source reduction” as defined in the Pollution Prevention Act of 1990 (42 U.S.C. 13102), and other practices that reduce or eliminate the creation of DOE-HDBK-1139/3-2008 xviii pollutants through (a) increased efficiency in the use of raw materials, energy, water, or other resources, or (b) the protection of natural resources by conservation. Precious Metal: A term that refers to gold, silver, and platinum group metals – platinum, palladium, rhodium, iridium, ruthenium, and osmium. Process Hazard Analysis: Hazard evaluation, as defined in 29 CFR 1910.119, Process Safety Management of Highly Hazardous Chemicals, subsection (e). 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 or 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 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 (SF) 120, excluding Hazardous Waste (see definition), Extremely Hazardous Property (see definition), Scrap (see definition), controlled substances (see definition), chemicals determined to be appropriate for abandonment or destruction, nuclear-related and proliferation-sensitive property (see definition), national security-sensitive property, and NRC-controlled materials. Reportable excess property includes non-hazardous chemicals, drugs and reagents other than controlled substances; nonfriable asbestos materials, and excluded PCB products (i.e., those containing less than 49 ppm PCB). 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 USC, Section 6901 et seq. DOE-HDBK-1139/3-2008 xix Safety Can: Approved container of not more than five-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): The person who 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: Perscribed period of time during which excess chemicals are offered for transfer or surplus chemicals are offered for donation to elegible recipants. Segregated Warehouse: A separate or detached building used specifically for warehousing-type operations. Senior Program Official or Designee: The person who 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 retain its properties such that it will function as intended when placed into service. Shelf-Life Item: Any item that deteriorates over time or has unstable characteristics such that a storage period must be assigned to ensure that the item is issued within that period to provide satisfactory performance. Management of such items is governed by 41 CFR 101-27.2, and by Department of Defense (DoD) instructions, for executive agencies and DoD respectively. 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 (SF): One of the U.S. Government forms; herein used to document and report disposition actions. 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 USC 484(j)). Storage: The act of setting aside chemicals 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 a facility after having undergone internal screening for reuse within the DOE complex as well as excess screening for transfer to another Federal agency. Surplus Property (Surplus): Excess personal property that is no longer needed by 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. DOE-HDBK-1139/3-2008 xx 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: The common name for the Comprehensive Environmental Response, Compensation, and Liability Act (CERCLA) (see definition) of 1980, as amended. System: Piping, pumps, or containers that collectively perform a specific function. Threshold Planning Quantity (TPQ): The minimum amount of a substance at which notification is required under 40 CFR 355. TPQs are listed in Appendices A and B of that regulation. Toxic Gas: Any gas with an NFPA health hazard rating of 3 or 4 (see definition) per NFPA 704, Identification System for Fire Hazards of Materials. Transuranic Waste: Transuranic (TRU) waste contains alpha-emitting radionuclides with the following characteristics: atomic number greater than 92, half-life greater than 20 years, and concentrations greater than 100 nCi/g (see definition). Trigger List8: 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 IAEA safeguards. Type I Items: Nonextendable shelf-life items with 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: A product that has been tested and certified by the Underwriters Laboratories (UL) to indicate that it conforms with UL safety standards. Universal Waste: Any of the following hazardous wastes that are managed under the universal waste requirements of 40 CFR 273: (1) batteries as described in 40 CFR 273.2; (2) pesticides as described in 40 CFR 273.3; (3) thermostats as described in 40 CFR 273.4; and (4) lamps as described in 40 CFR 273.5.

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. An unstable reactive chemical may also be identified as a Type I item (see definition). Examples include explosives, reactive monomers, and peroxide formers that produce unstable, highly friction-sensitive or shock-sensitive peroxides. 8 The Trigger List includes nuclear-grade graphite, deuterium, and heavy water. DOE-HDBK-1139/3-2008 xxi 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 spattering, pressure- volume explosions). It includes those materials that can form explosive mixtures with water. DOE-HDBK-1139/3-2008 xxii Acronyms and Abbreviations ACGIH: American Conference of Governmental Industrial Hygienists AHJ: Authority Having Jurisdiction AL: Acquisition Letter. ANSI: American National Standards Institute. ATF: Bureau of Alcohol, Tobacco, and Firearms CCLI: Commerce Control List Item CERCLA: 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 CRD: Contractor Requirements Document DEAR: Department of Energy Acquisition Regulation DoD: U.S. Department of Defense DOE: U.S. Department of Energy DOE-PMR: Department of Energy Property Management Regulations, 41 CFR 109 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 EPHA: Emergency Planning Hazards Assessment FAR: Federal Acquisition Regulation FEDS: Federal Disposal System FM: Factory Mutual FMR: Federal Management Regulation, (Title 41, Subtitle C), 41 CFR 102 FPMR: Federal Property Management Regulations, (Title 41, Subtitle C), 41 CFR 101 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 HMR: Hazardous Materials Regulations, 49 CFR 171 to 180 HSWA: The Hazardous and Solid Waste Amendments of 1984 to RCRA IC: Incident Commander ICS: Incident Command System IDLH: Immediate danger to life or health ISMS: Integrated Safety Management System LEPC: Local emergency planning committee MLI: Munitions List Item MSDS: Material Safety Data Sheet NFPA: National Fire Protection Association NIOSH: National Institute for Occupational Safety and Health DOE-HDBK-1139/3-2008 xxiii

NNSA: National Nuclear Security Administration NRC: Nuclear Regulatory Commission ODS: Ozone-Depleting Substance OPMO: Organizational Property Management Officer OSHA: Occupational Safety and Health Administration P2: Pollution Prevention PCB: Polychlorinated biphenyl PHA: Process Hazard Analysis PPL: Personal Property Letter RCRA: Resource Conservation and Recovery Act SARA: Superfund Amendments and Reauthorization Act of 1986 (see definition) SASP: State Agency for Surplus Property (see definition) scf Standard cubic feet SF: Standard Form TBD: To be determined at a later date TPQ: Threshold Planning Quantity TRU: Transuranic waste TSCA: Toxic Substances Control Act (15 USC 2601 – 2692) USC: United States Code DOE-HDBK-1139/3-2008 1 Chapter 1 - Hazard Analysis 1.1 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 DOE operations or 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), and the Compressed Gas Association (CGA) publications, the Occupational Safety and Health Administration (OSHA) standards, 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 or duplicative. The list of requirements includes “pointers” to the sources of those requirements. This document does not create any new or additional requirements. 1.2 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 operations or activities. It consolidates existing, core safety and health requirements that all sites must follow when engaged in chemical-related operations or activities. The requirements included in this chapter come from sources that have multiple, differing 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. Users are responsible for determining how specific requirements apply to their operational or activity 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 to accomplish an operation or activity. 1.3 Definitions and Acronyms See Glossary. DOE-HDBK-1139/3-2008 2 1.4 Requirements for Chemical Hazard Analysis Sources9 Consolidated Requirements10 4.1 General (Applicable to all operations/activities involving

chemicals) ANSI Z49.1, 3.2.2.2; CGA P-1, 4.1; NFPA 30, 5.2; NFPA 45, 7.1; NFPA 45, 7.2.1.1, NFPA 430, 2.-1.1; NFPA 432, 4.7.1; 10 Code of Federal Regulations (CFR) 835.204(d)(2); 10CFR 851.21; 29 CFR 1910.106(e)(8); 29 CFR 1910.146(c)(1)-(d)(2); 29 CFR 1910.1450(e)(3); 48 CFR 970.5204-2(c)(2)11 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 29 CFR 1910, Subpart Z.] 10CFR 851.26; NFPA 430, 2.1.1; NFPA 430, 2.10.1; NFPA 432, 4.7.1; 29 CFR 1910.132(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; 29 CFR 1910.1200(h)(1); 29 CFR 1910.1450(f)(1) and (f)(4)(i)(B) and (f)(4)(i)(C); 29 CFR 1926.21(b)(2) 4.1.2 Before beginning work, employees shall be informed of the hazards present in their work area. 4.2 Hazardous Operations12 (see definition) DOE O 151.1C, Attachment, Chap. IV, 3(a)(1): Attachment 2 4.2.1 Hazardous processes shall be analyzed for possible natural and man-made events that could lead to or result in a loss 9 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. 10 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. 11 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. 12 The requirements for hazardous operations are in addition to requirements associated with those activities specified in Section 4.1. DOE-HDBK-1139/3-2008 3 Sources9 Consolidated Requirements10 (CRD), sec. 3b(1); DOE O 420.1B, II.3.b(5) 10 CFR 830, Subpart B; 10 CFR 850.21(a); 10 CFR 1021.400; 29 CFR 1910.119(e); 29 CFR1910.120(c)(1); 40 CFR 68.50; 40 CFR 68.67(a); 40 CFR 1502.14 of control of hazardous materials. DOE O 151.1C, CRD, 3b(1); 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 DOE O 460.1A]; 10 CFR 830.7; 10 CFR 830 Subpart B, 204(a) and (b); 29 CFR 1910.119(e)(2); 40 CFR 68.67(b); 40 CFR 1502.24 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; 10 CFR 830 Subpart B, Part 202(b)(3); 29 CFR 1910.119(d); 29 CFR 1910.120(c)(3); 40 CFR 68.65; 40 CFR 1502.15 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); DOE O 151.1C, CRD, 3b(1); 10 CFR 830.204(b)(3); 29 CFR 1910.119(e)(3); 29 CFR 1910.120(c)(7); 40 CFR 68.22; 40 CFR 68.25; 40 CFR 68.28; 40 CFR 68.67(c); 40 CFR 1502.16; 40 CFR 1508.8

4.2.1.3 Consequences of postulated accidents associated with hazardous processes and their likelihood of occurrence shall be evaluated. 10 CFR 850.21(b); 29 CFR 1910.119(e)(4); 40 CFR 68.67(d) 4.2.1.4 Hazard analyses shall be performed by qualified personnel. 10 CFR 1021.310; 10 CFR 830 Subpart B, 204(a) and (b); 29 CFR 1910.119(e)(5); 4.2.1.5 Results of hazard analyses shall be documented and approved by appropriate management. DOE-HDBK-1139/3-2008 4 Sources9 Consolidated Requirements10 29 CFR 1910.120(b)(4); 40 CFR 68.39; 40 CFR 68.67(e); 40 CFR 1508.10 DOE O 151.1C, Ch IV, 3a(3): Attachment 2 (CRD), sec. 3b(1)(d) 10 CFR 830 Subpart B, 204(c)(1) and (c)(2); 29 CFR 1910.119(e)(6); 40 CFR 68.67(f) 4.2.1.6 Hazard analyses shall be updated and revalidated periodically. 10 CFR 830.6; 29 CFR 1910.119(e)(7); 40 CFR 68.67(g) 4.2.1.7 Hazard analysis results and documentation, including updates, shall be retained for the life of the process operation. 1.5 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 420.1B, Facility Safety 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 DOE O 460.1A] DOE-STD-1027-92, Hazard Categorization and Accident Analysis Techniques for Compliance with DOE Order 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 DOE-HDBK-1139/3-2008 5 P.L. 91-596, Sec 6(a), General Duty Clause of the Occupational Safety and Health Act of 1970 10 CFR 830, Nuclear safety management, Subpart B, Safety basis requirements 10 CFR 835, Occupational radiation protection 10 CFR 850, Chronic beryllium disease prevention program 10 CFR 851, Worker Safety and Health Program 10 CFR 1021, National Environmental Policy Act implementing procedures 29 CFR 1910.106, Flammable and combustible liquids 29 CFR 1910.119, Process safety management of highly hazardous chemicals 29 CFR 1910.120, Hazardous waste operations and emergency response 29 CFR 1910.132, Personal protective equipment 29 CFR 1910.146, Permit-required confined spaces 29 CFR 1910.1200, Hazard communication 29 CFR 1910.1450, Occupational exposure to hazardous chemicals in laboratories 29 CFR 1926.21, Safety training and education 40 CFR 68, Chemical accident prevention provisions 40 CFR 1500-1508, Chapter V–Council on Environmental Quality 48 CFR 970, DOE management and operating contracts DOE-HDBK-1139/3-2008 6 Chapter 2 – Acquisition 2.1 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 NFPA and OSHA standards, codes of fedral regualations of the Bureau of Mines, the Bureau of Alcohol, Tobacco, and Firearms, and certain EPA regulations and DOE Orders, including technical standards that are mandatory because of 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 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. This document does not create any new or additional requirements. 2.2 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. Users are responsible for determining how specific requirements apply 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. 2.3 Definitions and Acronyms See Glossary. DOE-HDBK-1139/3-2008 7 2.4 Requirements for the Acquisition of Chemicals Sources11 Consolidated Requirements12 4.1 General (Applicable to all acquisitions involving chemicals) 10 CFR 851.22(c); 48 CFR 970.5223-1 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. 10 CFR 1021; 48 CFR 970.5223-2 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 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. 29 CFR 1910.1200(g)(6)( iii); 29 CFR 1910.1200(g)(8); 29 CFR 1910.1450(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 29 CFR 1910.1450, other reference materials may be used. Additional Procurement Requirements (Non Health and Safety Requirements are provided for Informational purposes) 4.2 Alcohol 27 CFR 22.41; 48 CFR 908.7107 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 USC 167(d))); 30 CFR 602; 48 CFR 908.7108; 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." 4.4 Fuel and Petroleum 41 CFR 101-26.602; 48 CFR 908.7109 4.4.1 Acquisitions of fuel and packaged petroleum products by DOE offices and contractors shall be from Defense sources. 41 CFR 101-26.602; 48 CFR 908.7110 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 48 CFR 908.7111; 49 FR 11945, Mar. 28, 1984, 4.5.1 Acquisition of arms and ammunition readily procurable in the civilian market shall be made in accordance with local site DOE-HDBK-1139/3-2008 8 Sources11 Consolidated Requirements12 as amended at 49 FR 38950, Oct. 2, 1984 acquisition procedures. 4.6 DOE-specific materials acquisitions13 Contracting activities shall require authorized contractors to obtain the special materials identified in the following subsections in accordance with the procedures stated therein. 48 CFR 908.7121 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 metals14. 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 Lithium15. 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. 21 CFR 1316 4.7 Controlled Substances Use of controlled substances in research requires a permit or license. 2.5 Source Documents 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 USC 167(d)) NFPA 45 (2000) Standard on Fire Protection for Laboratories Using Chemicals 10 CFR 1021, National Environmental Policy Act implementing procedures 21 CFR 1316, Drug Enforcement Administration; administrative functions, practices, and procedures 27 CFR 22.41, Distribution and use of tax-free alcohol, qualification 29 CFR 1910.1200, Occupational safety and health standards – hazard communication 13 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. 14 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. 15 Lithium is available at no cost other than normal packing, handling, and shipping charges from the DOE Oak Ridge Operations Office. DOE-HDBK-1139/3-2008 9 29 CFR 1910.1450, Occupational safety and health standards – Occupational exposure to hazardous chemicals in laboratories 30 CFR 602, Bureau of Mines, Department of the Interior – Chapter VI, Subchapter A, Helium and Coal 41 CFR 101-26.602, Federal Property Management Regulations - Procurement Sources and Program 48 CFR, 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-1139/3-2008 10 Chapter 3 - Chemical Inventory and Tracking 3.1 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 OSHA standard and certain EPA regulations and DOE Orders, including technical standards that are mandatory because of their specific reference within a regulation, rule, or DOE Order. Direct requirements for a chemical inventory and tracking system are found in OSHA standard 29 CFR 1910.1200, and EPA regulation 40 CFR 370.25. In addition, there are many regulations and standards for which an inventory and tracking system is an implied requirement because 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 or duplicative. The list of requirements includes pointers to the sources of those requirements. This document does not create any new or additional requirements. 3.2 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 apply to the work being performed at an individual site or facility. Users are responsible for determining how specific requirements apply 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. 3.3 Definitions and Acronyms See Glossary. 3.4 Requirements for Chemical Inventory and Tracking DOE-HDBK-1139/3-2008 11 [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 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 standard 29 CFR 1910.6, which incorporates them by reference. 10 CFR 851 mandates compliance with OSHA regulations found in 29 CFR 1910. National standards requirements referenced here are thereby made mandatory for DOE contractors through contracts that include 10 CFR 851. Please see the Introduction to this section of the Chemical Management Handbook for more information.] Sources11 Consolidated Requirements12 4.1 Chemical Inventory Requirements 29 CFR 1910.1200(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 (MSDS) (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.] 40 CFR 370.25(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, or 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 (40 CFR 371.41) in lieu of the Tier I information. (Uniform Fire Code, Article 80, 8001.15; NFPA 45 7-2.3.3) NFPA 45, 7.2.3.3 4.1.3 For laboratories, chemical inventories shall be maintained within facility limits. 4.2 Implied Chemical Inventory Requirements. There are many mandatory standards that do not directly require an

inventory of hazardous chemicals, but for which 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 for tracking chemicals follows. The applicability of specific DOE Orders will depend on each site’s individual contract. 29 CFR 1910.38 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. 29 CFR 1910.1450 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 DOE-HDBK-1139/3-2008 12 Sources11 Consolidated Requirements12 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 startup of any new operation or task. 29 CFR 1910.1020 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 151.1C 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. 10 CFR 851 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 standards (29 CFR 1910 and 29 CFR 1926). 29 CFR 1910.119 4.2.6 Process Safety Management [PSM] of Highly Hazardous Chemicals. 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 420.1B, II.3.a(3) 4.2.7 Facility Safety. All new construction shall, at a minimum, conform to the Model Building Codes applicable for the state or region, supplemented with additional safety requirements associated with the facility hazards. Chemical inventories must be tracked in order to ensure that chemical limits specified in applicable regulations are not exceeded. DOE-HDBK-1139/3-2008 13 Sources11 Consolidated Requirements12 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 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 local building and fire codes. The DEAR Clause 4.2.9 DEAR 970.5204-2, Integration of Environment, Safety and Health into Work Planning and Execution. The contractor shall comply with and assist DOE 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 the terms of the 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 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)]. 10 CFR 830 4.2.10 Nuclear Safety Management. The documented safety analysis requires a systematic identification of all natural and manmade 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 its predecessor, Safety Analysis and Review System (DOE O 481.1B) for non-nuclear facilities. 40 CFR 68 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. 40 CFR 355 4.2.12 Emergency Planning and Notification. Establishes the list DOE-HDBK-1139/3-2008 14 Sources11 Consolidated Requirements12

of extremely hazardous substances, threshold planning quantities, and facility notification responsibilities necessary for development of state and local emergency response plans. 40 CFR 61; 40 CFR 63 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. 40 CFR 82 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. 3.5 Source Documents DEAR 970.5204-2, Integration of Environment, Safety and Health into Work Planning and Execution DOE O 151.1C, Comprehensive Emergency Management System DOE O 420.1B, Facility Safety 10 CFR 830, Nuclear Safety Management 10 CFR 851, Worker Safety and Health Program 29 CFR 1910.38, Employee Emergency Plans and Fire Prevention Plans 29 CFR 1910.119, Process Safety Management of Highly Hazardous Chemicals 29 CFR 1910.1020, Access to Employee Exposure and Medical Records 29 CFR 1910.1200, Hazard Communication 29 CFR 1910.1450, Occupational Exposure to Hazardous Chemicals in Laboratories 40 CFR 61, National Emission Standards for Hazardous Air Pollutants (NESHAPs) 40 CFR 63, National Emission Standards for Hazardous Air Pollutants for Source Categories 40 CFR 68, Chemical Accident Prevention Provisions 40 CFR 82, Protection of Stratospheric Ozone 40 CFR 355, Emergency Planning and Notification DOE-HDBK-1139/3-2008 15 40 CFR 370, Hazardous Chemical Reporting: Community Right-To-Know DOE-HDBK-1139/3-2008 16 Chapter 4 - On-Site Chemical Transportation 4.1 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 DOE O 460.1A], OSHA standards 29 CFR 1910.101, 29 CFR 1910.253, and 29 CFR 1926.350, ANSI standard ANSI Z49.1, and 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 or duplicative. The list of requirements includes pointers to the sources of those requirements. This document does not create any new or additional requirements. 4.2 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, Department of Transportation (DOT) rules apply. [NOTE: Throughout this document, the term “chemicals” is used to indicate chemicals 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. Users are responsible for determining how specific requirements apply 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. 4.3 Definitions and Acronyms See Glossary. DOE-HDBK-1139/3-2008 17 4.4 Requirements for On-Site Chemical Transportation Sources11 Consolidated Requirements12 DOE O 460.1A, 4.b; DOE O 460.1B 4.1 Onsite Hazardous Materials Transfers - shall comply with either: 49 CFR 171-180 4.1.1 the Hazardous Materials Regulations (HMR)(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 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 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 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 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 29 CFR 1910.101(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. 29 CFR 1910.253(b)(1)(i); 49 CFR 171-179 4.2.1.2 All portable cylinders used for the shipment of compressed gases shall be constructed and maintained in accordance with DOT regulations, 49 CFR 171-179. ANSI Z49.1; 29 CFR 1910.253(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.

CGA P-1, 3.4.2; 29 CFR 1926.350(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; 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, DOE-HDBK-1139/3-2008 18 Sources11 Consolidated Requirements12 29 CFR 1926.350(a)(2); 29 CFR 1910.253(b)(1)(iv) 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. 29 CFR 1926.350(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; 29 CFR 1926.350(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; 29 CFR 1926.350(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; 29 CFR 1926.350(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; 29 CFR 1926.350(a)(8) 4.2.1.10 When cylinders are moved at any time, the cylinder valve shall be closed. 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 *The CGA Pamphlet uses the word “should.” Because DOE incorporates the CGA documents by reference, the requirement may be interpreted as mandatory. DOE-HDBK-1139/3-2008 19 Sources11 Consolidated Requirements12 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 used to protect the cylinders from damage and 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. 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. 4.5 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 29 CFR 1910.101, Compressed Gases 29 CFR 1910.102, Acetylene 29 CFR 1910.253, Oxygen-Fuel Gas Welding and Cutting 29 CFR 1926.350, Gas Welding and Cutting DOE-HDBK-1139/3-2008 20 40 CFR 302.4, Listing of Hazardous Substances for the National Oil and Hazardous Substances Pollution Contingency Plan 49 CFR 171-180, Hazardous Materials Regulations (HMR) DOE-HDBK-1139/3-2008 21 Chapter 5 - Chemical Storage 5.1 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 ANSI Z49.1, CGA G-1 and CGA P-1, NFPA 30, NFPA 45, NFPA 51, NFPA 55, NFPA 430, NFPA 432, OSHA standards found at 29 CFR 1910.6, 29 CFR 1910.106, 29 CFR 1910.134, 29 CFR 1910.253, 29 CFR 1926.350, and 29 CFR 1910.1200. It includes requirements that are cited in either 10 CFR 851 or 29 CFR 1910.6 ("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 because the impact from these is considered to be negligible at DOE facilities. Similarly, EPA pesticide regulations are not addressed in this document because 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 or duplicative. The list of requirements includes pointers to the sources of those requirements. This document does not create any new or additional requirements. 5.2 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 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; or • 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 applicable to the work being performed at an individual site or facility. Users are responsible for determining how specific requirements apply to their work and how they are implemented. The reference sources for the DOE-HDBK-1139/3-2008 22 requirements included in this chapter can be used to determine the applicability of those requirements to the work being performed. 5.3 Definitions and Acronyms See Glossary. 5.4 Requirements for Chemical Storage Sources11 Consolidated Requirements12 10 CFR 851; 29 CFR 1910.6 [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 29 CFR 1910.6, which incorporates them by reference. 10 CFR 851 mandates compliance with OSHA standards found in 29 CFR 1910 and 1926. NFPA and CGA requirements referenced here are thereby made mandatory for DOE contractors through contracts that include 10 CFR 851. 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.16(Uniform Fire Code, Article 80, 8001.15; NFPA 45 7- 2.3.3) NFPA 430, 4.1.1; NFPA 430, 4.10.1; 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.17 NFPA 430, 4.6.2 4.1.2.1 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 manual fire fighting operations, building egress, and evacuation of adjacent facilities. NFPA 432, 4.7.2 4.1.2.2 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; 4.1.3 Chemical storage areas shall be secured using physical or administrative controls to prevent unauthorized entry. 18 16 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. 17 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. 18It is recommended that a graded approach be used in meeting this requirement. DOE-HDBK-1139/3-2008 23 Sources11 Consolidated Requirements12 NFPA 30, 6.7.4; NFPA 51, 2.2.1; NFPA 55, 7.1.3.2; 29 CFR 1910.253(b)(2) (ii); 29 CFR 1926.350(a)(11) CGA P-1, 4.2.1.5; NFPA 55, 7.6.3.2: NFPA 430, 4.9.2; 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, 6.10; NFPA 430, 4.9.1 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.19 NFPA 430, 4.2.4; 29 CFR 1910.1200(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; NFPA 55, 7.1.5.2; NFPA 430, 4.4.3.4; NFPA 430, 4.4.3; NFPA 430, 4.4.4 NFPA 432, 4.11.3.1 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. [EXCEPTION: NFPA 430, 4.4.3.1 exempts packaging materials, pallets, and other dunnage from this requirement. However, hydrogen peroxide (Classes II to IV) cannot be stored on wooden pallets per NFPA 430, 4.4.3.2.] 20 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, 4.4.3.3 4.1.7.2 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. 19 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. 20This 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 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-1139/3-2008 24 Sources11 Consolidated Requirements12 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 45, 7.2.3.6 NFPA 51, 2.2.2; NFPA 51, 2.3.2; NFPA 55, 6.17; 29 CFR 1910.106(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; 29 CFR 1910.106(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. NFPA 432, 4.9.1 4.1.10 Good housekeeping shall be maintained in areas where chemicals are stored. NFPA 30, 4.5.1.2; 29 CFR 1910.106(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, 6.7.4; NFPA 430, 4.13.1; NFPA 432, 4.-9.1 4.1.10.2 Accumulation of wastes, debris, weeds, and other combustible materials shall be prohibited. NFPA 430, 4.13.2; 4.9.2 4.1.10.3 Spilled chemicals and broken containers shall be immediately managed using appropriate procedures. NFPA 430, 4.13.3 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, 4.13.4 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 DOE-HDBK-1139/3-2008 25 Sources11 Consolidated Requirements12 (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. 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; 29 CFR 1910.253(b)(3)(i) 4.2.1.3 Signs shall prohibit smoking or an open flame within 20 feet 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; 29 CFR 1926.350(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 (e.g, damage from vehicles,damage from falling ice). 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; 29 CFR 1910.253(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 (SCBA).] 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. DOE-HDBK-1139/3-2008 26 Sources11 Consolidated Requirements12 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. 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.21 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; 29 CFR 926.350(a)(10); 29 CFR 926.350(a)(11); 29 CFR 1910.253(b)(2) (ii); 29 CFR 1910.253(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 feet or by a noncombustible partition with a fire- resistance rating of one-half hour and extending not less than 18 inches above and to the sides of the stored material. The noncombustible barrier shall be 5 feet high for those cylinders that are less than 3½ 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. However, 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 feet from storage of flammable and combustible liquids and solids. 29 CFR 1910.253(b)(3)(i)

4.2.7 The inside storage of more than 2,000 standard cubic feet (scf) of flammable gas, or more than 300 pounds of liquefied petroleum gas requires a separate room, compartment, or special storage building. 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. 21 This requirement includes the storage of compressed gas cylinders in direct sunlight where the sunlight may cause the cylinder to overheat. DOE-HDBK-1139/3-2008 27 Sources11 Consolidated Requirements12 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 feet 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 for toxic gases shall be located 75 feet from a line of property, public ways, or 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. 29 CFR 1910.134 4.2.14 Where toxic gases are stored, a minimum of two National Institute for Occupational Safety and Health (NIOSH)-approved 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. 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.22 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, 6.4.3.3; NFPA 30, 6.4.3.4; 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 feet wide. Aisles in other flammable liquid storage areas shall 22 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-1139/3-2008 28 Sources11 Consolidated Requirements12 29 CFR 1910.106(d)(4)(v) be 6 feet wide. 29 CFR 1910.106(d)(5) (vi)(f) 4.3.1.1 Aisles at least 3 feet wide shall be provided where necessary to allow for access to doors, windows, or standpipe connections. NFPA 30, 6.4.3.5; NFPA 30, 6.5.2.6 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, 6.4.3.1 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, 6.5.2.9 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, 6.5.2.9) 4.3.4.1 Ordinary combustibles, other than those used for packaging flammable liquids, shall be stored a minimum of 8 feet from flammable or combustible liquids. NFPA 30, 6.4.3.7 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, 6.4.3.8; 29 CFR 1910.106(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 6.4.3.8; 29 CFR 1910.106(d)(5)(vi)(d) 4.3.6.1 Portable tanks stored over one tier high shall be nested securely without dunnage. NFPA 30, 6.4.3.8 4.3.6.2 Material handling equipment shall be suitable to handle containers and tanks safely at the upper tier level. NFPA 30, 6.4.4.2; 29 CFR 1910.106(d)(4)(v) 4.3.7 Containers over 30 gallons in volume that contain Class I or Class II liquids shall not be stored over one level high in inside rooms (see definition). NFPA 30, 6.4.3.9; 29 CFR 1910.106(d)(5)(vi)(e) 4.3.8 No stack of flammable or combustible liquids shall be closer than 3 feet to the nearest beam, chord, or other construction, and shall be 3 feet below sprinkler deflectors, discharge orifices of water spray, or other overhead fire protection systems. NFPA 30, 6.9; 29 CFR 1910.106(d)(7)(i) 4.3.9 Suitable fire control devices shall be available at locations where flammable and combustible liquids are stored. 29 CFR 1910.106(d)(7) (i)(a); 29 CFR 1910.106(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. DOE-HDBK-1139/3-2008 29 Sources11 Consolidated Requirements12 NFPA 30, 6.9.1 NFPA 30, 6.10.1; 29 CFR 1910.106(d)(7)(iv) 4.3.11 Water-reactive materials (see definition) shall not be stored in the same area with flammable or combustible liquids.23 NFPA 30, 6.5.2.4 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, 6.5.1.3 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); 29 CFR 1910.106(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 follows24: 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. 150 gallons of Class I liquids in sprinklered laboratory units (see definition), and b. 200 gallons of Class I, II, and IIIA liquids in sprinklered laboratory units. [NOTE: The 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 4.3.13 and 4.3.14, 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, 6.3.1 4.3.15.1 The total quantity of liquids shall not exceed 120 gallons per cabinet. NFPA 30, 6.3.3 4.3.15.2 Flammable liquid storage cabinets shall be FM-approved, UL-listed or built in accordance with NFPA 30. NFPA 30, 6.3.2 4.3.15.3 Not more than three flammable liquid storage cabinets are allowed in any one fire area, except as follows: 23 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. 24 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-1139/3-2008 30 Sources11 Consolidated Requirements12 [EXCEPTION 1: In an industrial occupancy, 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 six 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 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, 6.6.4 4.3.16 Sites for outdoor storage lockers (see definition) shall be reviewed to ensure proper placement, separation, etc. NFPA 30, 6.6.4 4.3.16.1 Multiple outdoor storage lockers at a given site shall be separated according to requirements in NFPA 30. NFPA 30, 6.6.4.4.1 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, 6.6.4.4.2

4.3.16.3 No other flammable or combustible materials shall be stored at designated outdoor storage locker sites. NFPA 30, 6.6.4.4.3; 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, 4.2.1 4.4.1 Oxidizer storage areas shall be conspicuously identified with the words “Class (appropriate classification number) Oxidizers.” NFPA 430, 4.2.3 4.4.1.1 Areas used to store oxidizers of different classes shall be marked as containing the most severe hazard. NFPA 430, 4.11.6 4.4.2 Water-based, manual firefighting equipment shall be used in oxidizer storage areas.25 NFPA 430, 4.11.6.1 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 25Oxidizer 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. DOE-HDBK-1139/3-2008 31 Sources11 Consolidated Requirements12 can release chlorine are stored. NFPA 430, 4.11.6.2; NFPA 430, 4.11.6.3 4.4.2.2 Halon extinguishers shall not be used in oxidizer storage areas. NFPA 430, 4.12.1 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, 4.13.5 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, 4.4.6 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.26 NFPA 430, 4.8.1 4.4.5.1 Oxidizers will not be stored where they can come into contact with heating units, pipes, and ducts. NFPA 430, 4.4.3.5 4.4.6 Solid pxidizers shall not be stored directly beneath liquids. 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 to indicate the highest hazard level of the peroxides stored. 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. 7NFPA 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 feet shall be maintained between organic peroxide storage and uninsulated metal walls.

NFPA 432, 4.11.3.1 4.5.3 Incompatible materials and flammable liquids shall not be stored within 25 feet 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, 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 26 Attention should be used to ensure that oxidizers stored in direct sunlight are not heated above allowed temperatures by radiant heating. DOE-HDBK-1139/3-2008 32 Sources11 Consolidated Requirements12 for the materials being stored.27 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. 5.5 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 NFPA 30 (2003), Flammable and Combustible Liquids Code NFPA 45 (2004), 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 (2004), 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 10 CFR 851, Worker Safety and Health Program 27 Attention should be used to ensure that organic peroxides stored in direct sunlight are not heated above allowed temperatures by radiant heating. DOE-HDBK-1139/3-2008 33 29 CFR 1910.6, Incorporation by Reference 29 CFR 1910.106, Flammable and Combustible Liquids 29 CFR 1910.134, Respiratory Protection 29 CFR 1910.253, Oxygen-Fuel Gas Welding and Cutting 29 CFR 1910.1200, Hazard Communication 29 CFR 1926.350, Gas Welding and Cutting DOE-HDBK-1139/3-2008 34 Chapter 6 - Hazard Control 6.1 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 NFPA codes and standards, ANSI Z49.1, CGA P-1, OSHA standards, and certain EPA regulations and DOE 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. 6.2 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. Users are responsible for determining how specific requirements apply 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. 6.3 Definitions and Acronyms See Glossary. 6.4 Requirements for Hazard Control Sources11 Consolidated Requirements12 10 CFR 851 4.1 General (Applicable to all operations/activities involving DOE-HDBK-1139/3-2008 35 Sources11 Consolidated Requirements12 chemicals) 10 CFR 851.22 48 CFR 970.5204, 2(b)(6)28 4.1.1 A hazard prevention/abatement process shall be implemented to ensure that all identified hazards are managed through final abatement or control. 10 CFR 851.22(a)(1) 4.1.1.1 Controls shall be incorporated into facility design and procedures. 10 CFR 851.22(a)(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. 10 CFR 851.22(b); 29 CFR 1910.120(g)(1); 29 CFR 1910.134(a); 29 CFR 1910.1450(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 10 CFR 851.20(b) 29 CFR 1910.1200(h)(1-3); 29 CFR 1910.132(d) 4.1.1.4 Workers shall be informed of and involved in identifying and controlling workplace hazards, including decisions on selection of personal protective equipment (PPE). 10 CFR 851.21(a); 10 CFR 851.24(a); 10 CFR 851, Appendix A.6.; 29 CFR 1910.1450(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 Operations29 (see definition) DOE O 420.1B, II.3.b(2); DOE-STD-1120-98; DOE-STD-3009-94; DOE-STD-3011-94; DOE-STD-3016-99 10 CFR 830 Subpart B, 204(b)(4); 10 CFR 850.25(c); 29 CFR 1910.119(e)(3)(iii); 29 CFR 1910.120(c)(1); 29 CFR 1910.120(d) and (g)(1); 29 CFR 1910.252(a); 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 or mitigate adverse impacts from hazardous chemicals on workers, the public, or environment. 28 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. 29 The requirements for hazardous operations are in addition to requirements associated with those activities specified in Section 4.1. DOE-HDBK-1139/3-2008 36 Sources11 Consolidated Requirements12 40 CFR 68.67(c)(3); 40 CFR 1502.14; 40 CFR 1502.16 DOE O 420.1B, II.3.b.(2) 29 CFR 1910.119(f); 40 CFR 68.69(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. 29 CFR 1910.119(j); 40 CFR 68.73 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; 29 CFR 1910.119(f)(4); 29 CFR 1910.120(d) and (g)(1); 40 CFR 68.69(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. 29 CFR 1910.119(k) 40 CFR 68.85 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 29 CFR 1910.252(a) and shall have a permit that authorizes the work to be performed. 4.3 Requirements for Laboratory Use of Chemicals 29 CFR 1910.1450(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.

29 CFR 1910.1450(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 DOE-HDBK-1139/3-2008 37 Sources11 Consolidated Requirements12 appropriate, shall include: • Establishment of a designated area • Use of containment devices • Procedures for safe removal of contaminated waste • Decontamination procedures NFPA 45, 4.2.1.1 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, 4.2.1.3.1 4.3.2.1 For the purposes of determining laboratory fire hazard classification and the use of tables 10.1.1 10.1.5, 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, 6.1-6.6 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. NFPA 45, 7.1 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, 7.2 -7.5 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, 9.2 4.3.5 Handling of laboratory chemicals NFPA 45, 9.2.1.1 4.3.5.1 Chemicals shall not be brought into a laboratory work area unless design, construction, and fire DOE-HDBK-1139/3-2008 38 Sources11 Consolidated Requirements12 protection of the facilities are commensurate with the quantities and hazards of the chemicals involved. NFPA 45, 9.2.2.1 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, 9.2.2.4 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, 10.3.1 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 as follows: • 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; • In a liquid storage area specifically designed and protected for dispensing Class I flammable liquids that meet the requirements of NFPA 30. NFPA 45, 10.3.2 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, 10.3.3 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, 10.1.4 4.3.5.7 Individual containers of flammable or combustible liquids shall not exceed the capacities listed in NFPA 45, Table 10.1.4. NFPA 45, 9.3-9.5 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, 11.1.4-11.1.6 4.3.6 Laboratory compressed gases shall be used according to DOE-HDBK-1139/3-2008 39 Sources11 Consolidated Requirements12 requirements. NFPA 45, 11.1.4.1 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 NFPA 45, 11.1.4.2 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, 11.1.4.3 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, 11.1.5.2.1-2 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 11.6.4 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, 11.1.6.5 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. DOE-HDBK-1139/3-2008 40 Sources11 Consolidated Requirements12 (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. (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, 12.1.2-12.2.7.2 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; 29 CFR 1910.106(b)(6); 29 CFR 1910.106(e)(6)(1) 4.4.2 Precautions shall be taken to prevent the unintentional ignition of flammable vapors. NFPA 30, 7.9.2 4.4.2.1 Smoking shall be permitted only in designated and properly identified areas. NFPA 30, 7.9.3; 29 CFR 1910.106(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 DOE-HDBK-1139/3-2008 41 Sources11 Consolidated Requirements12 written permit authorizing such work has been issued. NFPA 30, 7.9.4; 29 CFR 1910.106(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. 29 CFR 1910.106(d)(2)(iii) 4.4.330 Individual containers of flammable or combustible liquids shall not exceed the capacities listed in 29 CFR 1910.106, Table H-12. NFPA 30, 6.5.5.2 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, 6.5.5.3 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). NFPA 30, 6.5.5.4 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, 6.5.5.5 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, 7.13.2.1 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. 29 CFR 1910.106(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, 7.13.4.1 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, 7.13.4.2 4.4.11 Those areas, including buildings, where a potential exists 30 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-1139/3-2008 42 Sources11 Consolidated Requirements12 for a flammable liquid spill shall be monitored for the presence of those liquids. NFPA 30, 7.13.6.1 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, 7.13.6.2; 29 CFR 1910.106(e)(9)(i) 4.4.13 Maintenance and operating practices shall control leakage and prevent spillage of flammable liquids. 29 CFR 1910.106(e)(9)(i) 4.4.14 Spills shall be cleaned up promptly. NFPA 30, 7.13.6.3; 29 CFR 1910.106(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. NFPA 30, 7.13.6.4; 29 CFR 1910.106(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, 7.13.6.5; 29 CFR 1910.106(e)(9)(ii) 4.4.17 Aisles established for movement of personnel shall be maintained clear of obstructions. NFPA 30, 7.5.2; 29 CFR 1910.106(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.] 29 CFR 1910.106(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. 29 CFR 1910.106(d)(4)(v) 4.4.20 Dispensing in inside storage rooms shall be by approved pump or self-closing faucet only. NFPA 30, 7.5.2.1 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, 7.5.2.2 4.4.22 Means shall be proved to minimize generation of static electricity. Such means shall meet the requirements of NFPA 30. 29 CFR 1910.106(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-1139/3-2008 43 Sources11 Consolidated Requirements12 NFPA 30, 7.5.2.3 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. 29 CFR 1910.106(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, 6.4.5.1 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 1,000 ft2 (93 m2) 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, 6.5.2.10 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. 29 CFR 1910.106(e)(2)(iv)(a) 4.4.28 Flammable liquids shall be kept in covered containers when not actually in use. 29 CFR 1910.106(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. 29 CFR 1910.106(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 29 CFR 1910.101 4.5.1 Compressed-gas cylinders shall be used in accordance with the CGA. NFPA 55, 4.2; 29 CFR 1910.253(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.

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; 29 CFR 1910.253(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 DOE-HDBK-1139/3-2008 44 Sources11 Consolidated Requirements12 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; 29 CFR 1910.253(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; 29 CFR 1926.350(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. ANSI Z49.1 10.8.4.13; 29 CFR 1910.253(b)(5)(ii)(L); 29 CFR 1926.350(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; 29 CFR 1926.350(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; 29 CFR 1910.253(b)(5)(ii)(M); 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. DOE-HDBK-1139/3-2008 45 Sources11 Consolidated Requirements12 29 CFR 1926.350(c)(2) 29 CFR 1926.350(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; 29 CFR 1910.253(b)(5)(ii)(N); 29 CFR 1910.253(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; 29 CFR 1910.253(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. 29 CFR 1910.253(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;

29 CFR 1910.253(b)(2)(ii); 29 CFR 1910.253(b)(2)(iii); 29 CFR 1910.253(b)(5)(ii)(G); 29 CFR 1910.253(b)(5)(ii)(H); 29 CFR 1926.350(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; 29 CFR 1910.253(b)(2)(iv); 29 CFR 1910.253(b)(5)(ii)(A); 29 CFR 1926.350(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. DOE-HDBK-1139/3-2008 46 Sources11 Consolidated Requirements12 CGA G-1, 5.5.1; CGA P-1, 3.4.3 4.5.9.1 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; 29 CFR 1910.253(b)(5)(ii)(C); 29 CFR 1926.350(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. 29 CFR 1926.350(a)(5) 4.5.10.1 Warm, not boiling water shall be used to thaw cylinders loose. ANSI Z49.1, 10.8.3.3; CGA P-1, 3.3.1; CGA G-1 5.1.10; 29 CFR 1910.253(b)(5)(ii)(K); 29 CFR 1926, 350(c)(1) 4.5.11 Compressed-gas cylinders shall not be used as rollers or supports. 29 CFR 1926. 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; 29 CFR 1910.253(b)(5)(ii)(J); 29 CFR 1926.350(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; 29 CFR 1926.350(b)(2); 29 CFR 1910.253(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; 29 CFR 1926.350(a)(7) and (9); 29 CFR 1926.350(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-1139/3-2008 47 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; 29 CFR 1910.253(3)(1); 29 CFR 1926.350(f)(1) 4.5.15 Oxygen, 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 or 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; 29 CFR 1926.350(d)(3); 29 CFR 1910.253(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. 29 CFR 1910.253(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; 4.5.20 Approved gas regulators and pressure reducing valves shall be used only for the gas and pressures for which they are labeled. DOE-HDBK-1139/3-2008 48 Sources11 Consolidated Requirements12 29 CFR 1910.253(a)(3); 29 CFR 1910.253(e)(6)(i) 29 CFR 1926.350(h) 4.5.21 Regulators, including their related gauges, shall be in proper working order while in use. ANSI Z49.1, 10.7.3; 29 CFR 1910.253(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; 29 CFR 1910.253(e)(6)(ii) 4.5.21.2 A qualified mechanic shall perform repairs 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; 29 CFR 1910.253(b)(5)(iii)(D); 29 CFR 1926.350(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; 29 CFR 1910.253(b)(5)(iii)(J); 29 CFR 1926.350(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. 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; 29 CFR 1910.253(b)(5)(ii)(E); 29 CFR 1910.253(b)(5)(iii)(L); 29 CFR 1926.350(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. 29 CFR 1926.350(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; 4.5.26 Cylinders having hand wheels shall not be opened using wrenches, hammers, or other tools. If the valve cannot be DOE-HDBK-1139/3-2008 49 Sources11 Consolidated Requirements12 CGA P-1, 3.8.1.1 ; CGA G-1, 5.3.3.2; 29 CFR 1910.253(b)(5)(ii)(Q)(1) 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; 29 CFR 1910.253(b)(5)(ii)(D); 29 CFR 1926.350(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; 29 CFR 1910.253(b)(5)(ii)(F); 29 CFR 1926.350(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; 29 CFR 1910.253(b)(5)(ii)(C); 29 CFR 1926.350(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; 29 CFR 1910.253(b)(5)(ii)(A); 29 CFR 1926.350(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. ANSI Z-49.1, 10.8.3.8; CGA G-1, 5.2.3; CGA P-1, 3.5. 2; 29 CFR 1910.252(b)(5)(ii)(A); 29 CFR 1926.350(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; 29 CFR 1910.253(b)(5)(ii)(B) and (O); 29 CFR 1910.253(b)(5)(iii)(B); 4.5.31 Compressed-gas cylinders shall not be purposely dropped, struck, or permitted to strike each other violently. DOE-HDBK-1139/3-2008 50 Sources11 Consolidated Requirements12 29 CFR 1926.350(a)(3) ANSI Z-49.1, 10.8.3.9; CGA G-1, 5.2.5; 29 CFR 1926.350(a)(4) and (9) 4.5.32 When compressed-gas cylinders are transported by motor vehicle, they shall be secured in an upright position. 29 CFR 1926.350(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; 29 CFR 1910.253(b)(5)(iii)(C); 29 CFR 1926.350(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; 29 CFR 1910.253(b)(5)(iii)(C); 29 CFR 1926.350(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; 29 CFR 1910.253(b)(5)(iii)(D); 29 CFR 1926.350(d)(1) 4.5.34.2 Fuel cylinder valves shall not be cracked near ignition sources such as flames, welding work, sparks, etc. 29 CFR 1926.350(e)(3) 4.5.34.3 Hose connections shall be kept free of grease and oil. ANSI Z 49.1, 10.6.1; 29 CFR 1910.253(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; 29 CFR 1926.350(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; 29 CFR 1910.253(e)(5)(ii); 29 CFR 1926.350(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; 29 CFR 1910.253(e)(5)(v); 29 CFR 1926.350(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; 4.5.39 Hose connections shall comply with the CGA Pamphlet E- DOE-HDBK-1139/3-2008 51 Sources11 Consolidated Requirements12 29 CFR 1910.253(e)(5)(iii) 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; 29 CFR 1910.253(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; 29 CFR 1910.253(e)(5)(iv) 4.5.39.3 Oil-free air or an oil-free inert gas shall be used to test hose connections. 29 CFR 1926.350(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; 29 CFR 1910.253 4.5.40 Fuel gas and oxygen manifolds capacity limits, locations and design criteria shall be in accordance with NFPA 51 and 29 CFR 1910.253. CGA G-1, 5.1.4; 29 CFR 1910.253(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; 29 CFR 1910.253(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; 29 CFR 1910.253(c)(1)(i) 4.5.42.1 Manifolds shall be approved either separately for each of their components or as an assembled unit. 29 CFR 1926.350(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. 29 CFR 1926.350(e)(2) 4.5.44 Fuel gas and oxygen manifolds shall be located in safe, well ventilated, accessible locations and not within enclosed spaces. 29 CFR 1926.350(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. 29 CFR 1926.350(e)(3) 4.5.45.1 Adapters shall not be used to permit the interchange of hoses. 29 CFR 1926.350(e)(4) 4.5.46 When not in use, fuel gas and oxygen manifold and header connections shall be capped. 29 CFR 1926.350(3)(5) 4.5.47 Nothing shall be placed on top of a fuel gas and oxygen DOE-HDBK-1139/3-2008 52 Sources11 Consolidated Requirements12 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. ANSI Z-49.1, 10.3.1; CGA P-1, 4.4.1; 29 CFR 1910.253(b)(5)(i); 29 CFR 1926.350(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. 29 CFR 1910.253(b)(5)(I); 29 CFR 1926.350(h)(i) 4.5.49.1 A jet of oxygen gas shall not be directed at an oily surface, greasy clothes, etc. ANSI Z49.1, 10.7.4; 29 CFR 1910.253(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 4.5.53 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 4.5.54 Oxygen in work areas shall not be allowed to exceed 23 percent by volume. ANSI Z49.1, 10.8.2.5; 29 CFR 1910.253(b)(3)(ii); 29 CFR 1910.253(b)(5)(iii)(A) 4.5.55 Fuel gas cylinders shall be used valve end up. NFPA 55, 7.6.3.1 4.5.56 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; 29 CFR 1910.253(b)(5)(iii)(E); 29 CFR 1926.350(d)(2) 4.5.57 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; 29 CFR 1910.253(b)(5)(iii)(K); 29 CFR 1926.350(d)(2) 4.5.57.1 Quick opening valves on fuel gas cylinders shall be opened between ¾ and 1½ 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. ANSI Z49.1, 10.8.5.1; 4.5.59 If a leak is found around the valve stem of a fuel gas DOE-HDBK-1139/3-2008 53 Sources11 Consolidated Requirements12 CGA G-1, 5.6.2; 29 CFR 1926.350(d)(5) cylinder, the packing nuts shall be tightened and the cylinder valve closed. ANSI Z49.1, 10.8.5.2; CGA G-1, 5.6.3; 29 CFR 1910.253(b)(5)(iii)(F); 29 CFR 1926.350(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; 29 CFR 1910.253(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; 29 CFR 1910.253(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 29 CFR 1910.102 4.5.62.1 Acetylene 29 CFR 1910.103 4.5.62.2 Hydrogen 29 CFR 1910.104 4.5.62.3 Oxygen 29 CFR 1910.105 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.

29 CFR 1910.1014 4.6.1 2-Acetylaminofluorene 29 CFR 1910.1045 4.6.2 Acrylonitrile 29 CFR 1910.1011 4.6.3 4-Aminodiphenyl 29 CFR 1910.1018 4.6.4 Arsenic, inorganic 29 CFR 1910.1001 4.6.5 Asbestos 29 CFR 1910.1028 4.6.6 Benzene DOE-HDBK-1139/3-2008 54 Sources11 Consolidated Requirements12 29 CFR 1910.1010 4.6.7 Benzidine 10 CFR 850 4.6.8 Beryllium 29 CFR 1910.1051 4.6.9 1,3-Butadiene 29 CFR 1910.1027 4.6.10 Cadmium 29 CFR 1910.1008 4.6.11 bis-Chloromethyl ether 29 CFR 1910.1044 4.6.12 1,2-dibromo-3-chloropropane 29 CFR 1910.1007 4.6.13 3,3’-Dichlorobenzidine (and its salts) 29 CFR 1910.1015 4.6.14 4-Dimethylaminoazobenzene 29 CFR 1910.1012 4.6.15 Ethyleneimine 29 CFR 1910.1047 4.6.16 Ethylene oxide 29 CFR 1910.1048 4.6.17 Formaldehyde 29 CFR 1910.1025 4.6.18 Lead NFPA 484 4.6.19 Lithium NFPA 484 4.6.20 Magnesium solids and powders 29 CFR 1910.1006 4.6.21 Methyl chloromethyl ether 29 CFR 1910.1052 4.6.22 Methylene chloride 29 CFR 1910.1050 4.6.23 Methylenedianiline 29 CFR 1910.1004 4.6.24 alpha-Naphthylamine 29 CFR 1910.1009 4.6.25 beta-Naphthylamine 29 CFR 1910.1003 4.6.26 4-Nitrobiphenyl 29 CFR 1910.1016 4.6.27 N-Nitrosodimethylamine 29 CFR 1910.1013 4.6.28 beta-Propiolactone NFPA 484 4.6.29 Titanium 29 CFR 1910.1017 4.6.30 Vinyl chloride NFPA 484 4.6.31 Zirconium 6.5 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 420.1B, Facility Safety 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 (2003), Flammable and Combustible Liquids Code NFPA 45 (2004), Standard on Fire Protection for Laboratories Using Chemicals DOE-HDBK-1139/3-2008 55 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 10 CFR 830, Nuclear Safety Management, Subpart B, Safety Basis Requirements 10 CFR 850, Chronic Beryllium Disease Prevention Program 10 CFR 851, Worker Safety and Health Program 10 CFR 1021, National Environmental Policy Act Implementing Procedures 29 CFR 1910.101, Compressed Gases (general requirements) 29 CFR 1910.102, Acetylene 29 CFR 1910.103, Hydrogen 29 CFR 1910.104, Oxygen 29 CFR 1910.105, Nitrous oxide 29 CFR 1910.119, Process Safety Management of Highly Hazardous Chemicals 29 CFR 1910.120, Hazardous Waste Operations and Emergency Response 29 CFR 1910.132, Personal Protective Equipment 29 CFR 1910.134, Respiratory Protection 29 CFR 1910.253, Oxygen-Fuel Gas Welding and Cutting 29 CFR 1910.1001, Asbestos 29 CFR 1910.1003, 13 Carcinogens (4-Nitrobiphenyl, etc.) 29 CFR 1910.1004, alpha-Naphthylamine 29 CFR 1910.1006, Methyl chloromethyl ether 29 CFR 1910.1007, 3,3’-Dichlorobenzidine (and its salts) 29 CFR 1910.1008, bis-Chloromethyl ether 29 CFR 1910.1009, beta-Naphthylamine 29 CFR 1910.1010, Benzidine

DOE-HDBK-1139/3-2008 56 29 CFR 1910.1011, 4-Aminodiphenyl 29 CFR 1910.1012, Ethyleneimine 29 CFR 1910.1013, beta-Propiolactone 29 CFR 1910.1014, 2-Acetylaminofluorene 29 CFR 1910.1015, 4-Dimethylaminoazobenzene 29 CFR 1910.1016, N-Nitrosodimethylamine 29 CFR 1910.1017, Vinyl Chloride 29 CFR 1910.1018, Inorganic Arsenic 29 CFR 1910.1025, Lead 29 CFR 1910.1027, Cadmium 29 CFR 1910.1028, Benzene 29 CFR 1910.1044, 1,2-dibromo-3-chloropropane 29 CFR 1910.1045, Acrylonitrile 29 CFR 1910.1047, Ethylene Oxide 29 CFR 1910.1048, Formaldehyde 29 CFR 1910.1050, Methylenedianiline 29 CFR 1910.1051, 1,3-Butadiene 29 CFR 1910.1052, Methylene Chloride 29 CFR 1910.1200, Hazard Communication 29 CFR 1910.1450, Occupational Exposure to Hazardous Chemicals in Laboratories 29 CFR 1926.21, Safety Training and Education 40 CFR 68, Chemical Accident Prevention Provisions 48 CFR 970, DOE Management and Operating Contracts DOE-HDBK-1139/3-2008 57 Chapter 7 – Sustainable Pollution Prevention and Waste Minimization Activities 7.1 Introduction This chapter identifies and consolidates existing user safety, health, and environmental 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 U.S. Code (USC), 40 CFR “Protection of the Environment”; Executive Order 13423, Strengthening Federal Environmental, Energy and Transportation Management; draft DOE O 450.1A, Environmental Protection Program; DOE Acquisition Guide Chapter 23 (June 2007); 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, health, and environmental requirements and to consolidate those that are overlapping or duplicative. The list of requirements includes pointers to the sources of those requirements. 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 programs and environmental pollution prevention programs are usually mutually beneficial, and their requirements frequently mutually inclusive. The consolidated chemical-related safety and health requirements listed here provide context for chemical user requirements to incorporate pollution prevention into every phase of work, such as planning, acquisition, operations, waste management and disposal, and to seek continuous improvement in pollution prevention and waste minimization. Achieving the requirements for pollution prevention involves integrating P2 into planning, execution, and evaluation of site activities, and is done through integrating the site environmental management system (EMS) into the site Integrated Safety Management system. This chapter does not contain requirements for implementation of EPA reporting requirements or for environmental regulatory compliance. This document does not create any new or additional requirements. 7.2 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 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. Users are responsible for determining how specific requirements apply to their DOE-HDBK-1139/3-2008 58 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. 7.3 Definitions and Acronyms See Glossary in this Volume. 7.4 Requirements for Sustainable Pollution Prevention and Waste Minimization Activities Sources11 Consolidated Requirements12 4.1 Hazardous Waste Generator Requirements Hazardous and Solid Waste Amendments Act(HSWA) sec. 3005(h)(i); 40 CFR 264.73(b)(9); 40 CFR 262, 264-265; 40 CFR 270; 42 USC sec. 6922(b) and 6925 (h) 4.1.1 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.31 HSWA 3002, sec. (a)(6)(C)- (D); 40 CFR 262.41(a)(6)-(7); 40 CFR 264.75(h)-(i); 40 CFR 265.75(h)-(i); 42 USC sec. 6922 (a)(6) 4.1.2 A chemical user who generates hazardous waste is required to submit biennial reports describing: a) efforts undertaken to reduce the volume and toxicity of waste generated; and b) changes in volume and toxicity of waste actually achieved compared with previous years, to the extent that such information is available. 4.2 Sustainable Environmental Stewardship Objectives and Policy DOE O 450.1A, sec. 1a,b, Contractors Requirements Document (CRD) sec. 1a(2) and 1b(1) 4.2.1 DOE objectives: To implement sustainable practices for enhancing environmental, management performance, as stipulated in Section 3(a) of Executive Order 13423, through environmental management systems (EMS) that are part of Integrated Safety Management (ISM) systems established pursuant to DOE P 450.4 dated 10-15- 96; and to achieve the DOE Sustainable Environmental Stewardship goals found in 31 This is an implied or indirect requirement to have a waste and toxicity reduction program. The actual requirement is for a certifying signature on hazardous waste manifests; on permits for treatment, storage, or disposal of hazardous waste; and in Hazardous Waste Generator Biennial Reports as to the existence of a waste and toxicity reduction program. A violation would be for false certification of the existence of a waste and toxicity reduction program, rather than for not having the program. DOE-HDBK-1139/3-2008 59 Sources11 Consolidated Requirements12 Attachment 2 of DOE Order 450.1A. EO 13423, sec. 1 4.2.2 It is the policy of the United States that Federal agencies conduct their environmental activities under the law, in support of their respective missions in an environmentally, economically, and fiscally sound, integrated, continuously improving, efficient and sustainable manner.

4.3 Sustainability and Environmental Management Systems EO 13423, sec. 3a(b); DOE O 450.1A , sec. 4a and b(2); CRD sec. 1a(2) 4.3.1 Each DOE site must develop and implement an EMS which must include environmental objectives and measurable targets that are updated when appropriate and contribute to achieving the DOE Sustainable Environmental Stewardship goals found in Attachment 2 of DOE Order 450.1A, and which address tenant or other activities that affect the Department’s environmental management. EO 13423, sec. 3a(iv)(v)(vii); CRD sec. 1b(1); DOE O 450.1, sec. 4(c)1, Attachment 2 4.3.2 DOE sites shall implement sustainable practices for: • acquisition • pollution and waste prevention and recycling, and • reduction or elimination of acquisition and use of toxic or hazardous chemicals and materials. 4.4 Sustainable Environmental Stewardship Goals EO 13423, sec. 2(d) and (e); DOE Acquisition Guidce, chapter 23, page 9, 10; DOE O 450.1A, Attachment 2 4.4.1 DOE shall require in agency acquisitions of goods and services (i) use of sustainable environmental practices, including acquisition of biobased, environmentally preferable, and recycled-content products. 4.4.2 DOE shall ensure that it reduces the quantity of