definitions - iosh

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DSEAR and COMAH Awareness for IOSH

20th April 2017

► Dangerous Substance► Explosive, extremely flammable, highly flammable or flammable

substance i.e. Any substance capable of forming an explosive atmosphere in air

► ATEX► The term used to refer to the EU Atmosphères Explosibles

Directives

► DSEAR► Dangerous Substances and Explosive Atmospheres Regulations

► COMAH► Control of Major Accident Hazards

Definitions

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Acetylene Fire

COMAH Addresses Larger Hazards

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Legislation

► Control of Major Accident Hazards Regulations 2015

► Implement Directive 2012/18/EU (Seveso Directive)

► Aim to limit the potential for major accident hazards at industrial sites and ensure appropriate measures are in place for emergency response

► Came into force 1st June 2015, replacing the 1999 Regulations

UK Regulation - COMAH

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► A COMAH site is one that stores a sufficient quantity of dangerous substances to fall into the definition of an ‘Upper Tier’ or ‘Lower Tier’ site.

► Schedule 3 of the Regulations provides the substances and stored quantities that may qualify a site as a COMAH establishment.

► There are 48 named substances as well as substance groups with associated threshold quantities to determine whether a site is upper or lower tier.

What is a COMAH site?

► Duties relevant to all sites► Notification

► Hazardous Substances Consent (HSC)

► Major Accident Prevention Policy (MAPP)

► All measures necessary

► Duties relevant to Upper Tier sites► Prepare a COMAH safety report

► Prepare and test an on-site emergency plan

► Supply information to local authorities for off-site emergency planning purposes

► Provide certain information to the public

COMAH – Summary of the Main Requirements

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► A COMAH Safety Report demonstrates how a high hazard site controls the risks associated with the materials and processes on site.

► The Safety Report includes a risk assessment to identify and understand the hazards on site.

► The other sections of the Safety Report then demonstrate the systems in place to control these hazards and mitigate their consequences.

► The preparation of a Safety Report will highlight any shortfalls in the physical plant, its operation, management systems or emergency preparedness.

COMAH Safety Report

► Named Substances

► Hydrogen

► Chlorine

► Hydrogen Sulphide

► Oxygen

► 3-(2-Ethylhexyloxy)propylamine

► Categories

► Health Hazards: H1, H2, H3 (Toxics)

► Physical Hazards: P1 – P8 (Explosives, flammables, oxidisers, self reactive chemicals, peroxides and pyrophoric compounds)

► Environmental Hazards: E1, E2

► Other Hazards: O1 – O3 (Substances carrying specific hazard statements)

Substances

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► COMAH substances can be restrictive, other hazardous materials and processes may be present on site

► Should be identified through compliance with other regulations such as DSEAR, COSHH, HSWA

► It is important to have systems in place to identify these hazards

► A non-COMAH substance is not non hazardous!

Substances

► Introduction of Globally Harmonised System (GHS) labelling led to reclassification of substances and potential changes to site COMAH status.

► Changes to requirements for emergency response planning

► Public information requirements for lower tier sites

► Changes to the Safety Report Assessment Manual (SRAM) criteria requiring greater detail and supporting evidence to be supplied within the Safety Report

The 2015 Regulations came into force on the 1st

June 2015, with the HSE demanding much more from the Safety Reports in terms of supporting evidence, particularly for the ALARP demonstration.

2015 Regulations

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► Cristal Pigment UK Limited – £3 m (October 2016)

► Roxel (UK Rocket Motors) Ltd – £386,000 (July 2016)

► Buncefield

► Total £3.6m with £2.6m costs

► Hertfordshire Oil Storage Limited £1.45m with £1m costs

► British Pipeline Agency Ltd £300k fine £480k costs

► Ineos Enterprises Group –Improvement Notice

► Contract Chemicals –Improvement Notice

► Valtris Speciality Chemicals Limited – Improvement Notice

COMAH Prosecutions and Enforcement

► PLUS costs of reworking Safety Reports – HSE charge for reviewing and inspecting so repeat work is extra cost!

► Dangerous Substances and Explosive Atmospheres Regulations 2002

► Enacts ATEX 1999/92/EC into UK law

► Aim was to harmonise standards across EU

► Regulations came into force in Dec 2002

UK Regulation – DSEAR

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► Very few COMAH sites are not subject to DSEAR

► Compliance with DSEAR is a benchmark for the Process Safety technical criteria and is also considered as part of Mechanical criteria

► As part of the demonstration for Regulation 5, all sites must consider any benchmark standards

► DSEAR assessment will cover substances and events outside the scope of COMAH e.g. dust explosions

► Control of ignition sources is a key safeguard against major accident scenarios involving flammable substances

Importance of DSEAR

► Regulation 5 – Requires employers and the self-employed to assess risks to employees and others whose safety may be affected by the use or presence of dangerous substances at work (Risk Assessment)

► Regulation 6 – Sets out how the risk to safety from dangerous substances should be eliminated or reduced (Elimination & Risk Reduction)

► Regulation 7 – Contains specific requirements to be applied where an explosive atmosphere may be present (in addition to the requirements in Regulation 6) (Area Classification & Equipment Selection)

► Regulation 8 – Requires the provision of arrangements to deal with accidents, incidents and emergencies (Arrangements)

► Regulation 9 – Requires the provision of information, training and instruction on dangerous substances (Information & Training)

► Regulation 10 – Requires the identification of pipes and containers where these contain dangerous substances (Hazard Contents)

DSEAR – Summary of the Main Regulations

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► Batley Foundry Limited –£15,000 (August 2016)

► Sears Manufacturing Co (Europe) Ltd – £40,000 (April 2016)

► SAFC Hitech – £120,000 (April 2013)

► Redmondis UK Ltd –Improvement Notice

► Catalloy Limited –Improvement Notice

► Itac Ltd – Immediate Prohibition Notice

► Delamere Cabinet Makers Ltd – Immediate Prohibition Notice

► Bosley Wood Mill –Immediate Prohibition Notice (Fatal Accident August 2015)

DSEAR Prosecutions and Enforcement

Flammable Substances

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► In teams, try and identify:-

► What flammable substances are used on your site ?► Gases

► Liquids

► Dusts

Flammable Substances

‘lowest liquid temperatureat which, under certain standardized conditions, a liquid gives off vapours in a quantity such as to be capable of forming an ignitable vapour / air mixture’

► Petrol FP = -40°C

► Diesel FP = 50°C

► Ethanol ► Port FP = 38°C

► Whisky FP = 29°C

► Absinthe FP = 13 °C

Flash Point

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Flammable Ranges of Typical Materials

0

Methane

Propane

Hydrogen

Acetylene

2010 30 40 50 60 70 80 90 100

Percentage of Explosive (Flammable) at STPGas or Vapour in Air

Carbon Monoxide

► The Auto-ignition Temperature of a chemical is the lowest temperature at which a material will ignite without an external source of ignition.

► Lube oil – 230°C

► Diesel – 230°C

► Methane – 540°C

► Hydrogen – 560°C

► Ammonia – 630°C

Auto Ignition Temperature (AIT)

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► Minimum quantity of Energy to needed to Ignite an ‘Ideal’ mixture of a specific flammable Gas, vapour or dust and air’

► This is normally measured in microjoules (μj) and varies from substance to substance

► Typical gas and vapour values lie between 20 and 300 microjoules

► Typical dust values lie between 1000 and 50000 microjoules

Ignition energy

► Dusts can ignite in either layer or cloud form

► Dusts and vapours behave differently:

► spread of flammable atmosphere

► sensitivity to ignition

► Gas or vapour cloud eventually dispersed by ventilation

► Dust emission creates cloud, settles as layer, can be disturbed as a cloud again

► Risk assessment and Area classification should take this into account

Flammable Properties of Dust

2 m

Flammable dust cloud

25 W

Glass

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Imperial Sugar

Why did this happen?

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Risk Assessment

► Every activity involving a dangerous substance MUST have a risk assessment in place

► It should consider

► The consequence of a fire or explosion

► It must identify

► A basis of safety

► The activity should only go ahead if the risks are tolerable

► Overlap with COMAH

► Be sure not to duplicate risk assessments

► COMAH RA’s may miss DSEAR scenarios e.g. flammable gas cylinders, gas metering houses etc.

Risk Assessment

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DSEAR Hierarchy of Control

Prevent Flammable Atmosphere Formation

Control Ignition sources

Mitigate Effects of Explosion/Fire

► How can we prevent a flammable atmosphere forming?

► Substitute by less or non-hazardous materials

► Limit amount of flammable materials

► Containment

► Ventilation to extract, dilute or disperse

Prevention

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► What ignition sources can you think of?

► How can they be controlled?

► Electrical equipment► Normal Operation► Faults

► Mechanical equipment

► Sparks► Friction

► Hot surfaces► Vehicle engines► Reformer tubes

► Naked Flames

Control of Ignition Sources

► Certified equipment► Haz area inspection

► Retrospective assessment

► Maintenance procedures

► Certified equipment

► Restrictions on access► Can’t be controlled!

► Hot work controls► Smoking

► How can the effects of a fire or explosion be mitigated?

► Exclude people from the zones

► Deluge systems

► ROSOVs

► Engineering measures

► Explosion panels or suppression

► Pressure containment

► PPE

► Emergency response

Mitigation of Effects

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Mitigation of Effects

Is the Risk Tolerable?

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Vehicle Impact With Hydrogen Cylinders


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► Eliminate hydrogen from the process

► Eliminate vehicles from the site

► Control ignition sources

► Pipe in the hydrogen from an alternative location, removing all portable cylinders

► Install robust crash barriers

► Relocate the cylinder bank behind the wall

Ways to reduce the risk


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Sample Actions Arising From DSEAR RAs


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Hazardous Area Classification

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► An area in which an explosive gas, mist or dust atmosphere is or may be expected to be present, in quantities such as to require special precautions for the construction, installation and use of equipment

► The process to identify these areas is Area Classification

► So as to select equipment for installation within these areas that has been designed, constructed and tested so as to prevent means of ignition

Hazardous Area

► Zone 0/ 20

► present continuously

► or for Long periods

► or frequently

► Zone 1/ 21

► Likely to occur in Normal operation occasionally

► Zone 2/ 22

► Not likely to occur in Normal operation and will persist for a short time

Area Classification – Zones

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Sample HAC Drawing

Area Classification in practice

SolventStorage

Tank

AgitatedReactorVessel

SingleMechanicalSeal Pump

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Points of Emission

SolventStorage

Tank



Zone

SolventStorage

Tank



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2

2

0

2

22

1

1

1

0

1/0

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Hazardous Area Equipment

Equipment Marking – New Equipment

II G2

Equipment Group

Category

Gas

IIB T3εx

Gas Group

TemperatureRating

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Zone Category

0 1

1 1 & 2

2 1, 2 & 3

Equipment Categories

Which zones could equipment bearing these nameplates be used in?

Equipment Selection

II G3εx

II G2εx

Zone 2

Zone 1 and 2

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ATEX Nameplate

► Built to:-

► Not create an ignition source

► Keep out flammable gases or dusts

► Contain an explosion

► Must be correctly specified, installed and repaired by competent people

► Many apparatus types require routine maintenance or inspection to ensure safe use

Electrical Equipment

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► Built to:-

► Not create an ignition source

► Contain an explosion

► Must be correctly specified, installed and repaired by competent people

► Many apparatus types require routine maintenance or inspection to ensure safe use

► Pre 2003 equipment can continue to be used if assessed for suitability

Mechanical Equipment

Equipment Ignition Sources

Oiled Bearings

Single Flushed Seal

Tyre coupling and Guard

Electric Motor

Pumping hot oil at 280°C in a T3 Area

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► Ignition Source

► Shaft snapping

► Bearing heating up

► Seal dry running

► Coupling catching on guard

► Motor sparking

► Hot surface

► Static accumulation

► Normal Operation or failure

► Rare failure

► Expected failure



► Normal operation



Equipment Ignition Sources

► Earth all conductors

► Fixed equipment to a known earth

► Mobile equipment with grounding clamps –Earth before introducing flammables!

► Wear the standard issue dissipative footwear

► Tester to be installed

► Avoid insulating materials

► Plastic containers larger than 5L

► Other plastic items unless assessed

► Remove accumulation mechanism

► No splashing liquids

► Relaxation time for insulating liquids

Electrostatic Ignition Sources

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► Warnings before entering an area

► Likely to be reviewed across the site.

► Ensure you and any visitors understand what they mean:-

► No unauthorised sources of ignition

► Correct PPE

Signage

► All equipment and containers must be identifiable

► Marking and labelling to be improved

► Training

► Ensure containers are not stored in the wrong store or location (e.g. flammable pressurised cylinders not stored with oxygen)

Identification of Equipment and Containers

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► If you are a COMAH site, likely to be driven by COMAH requirements

► Ensure planned response is proportionate to risk.

► Consider life safety first but also consider environmental effects and asset protection.

► Don’t rely on the fire service to protect your business – they will save lives but not risk themselves to preserve assets.

Emergency Response

If All Else Fails – RUN!

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RPS Risk Management105 Dalton AvenueBirchwood ParkWarringtonWA3 6YFTel: +44 (0) 1925 831000

Steve SherwenE-mail: [email protected] +44(0) 7483 939 200

Louise PlattE-mail: [email protected] +44(0) 7774 193 628

Any Questions?

definitions - iosh

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