guy colonna, p.e. 55 th annual mca seminar bar harbor, me july 16, 2013
TRANSCRIPT
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Guy Colonna, P.E.55th Annual MCA Seminar
Bar Harbor, MEJuly 16, 2013
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Cadillac Mountain, Acadia National Park
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AgendaBackground
Confined space statisticsRecent incidents – CSB issues
OSHA 29 CFR 1910.146, Permit-Required Confined Spaces - overview
Aboveground Storage TanksAPI resourcesTES Certification programPractical issues
Marine Chemist roleClosing
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PRE-INVENTORY1. An OSHA confined space has the following:
a) large enough to permit entryb) intended for continuous occupancyc) normal atmospheric ventilationd) limited or restricted entry or exit
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PRE-INVENTORY2. The following are tank classifications found
in OSHA 29 CFR 1910.146, Permit Required Confined Spaces.
a) Non-confined spaceb) Non-permit required confined spacec) Permit required confined space
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PRE-INVENTORY3. API 2015 and 2016 use which of the
following safety designations?a) Enter with restrictionsb) Enter without restrictionsc) Enter with special precautionsd) Enter when inertede) All of the above
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PRE-INVENTORY4. What is the maximum safe level of oxygen
according to 29 CFR 1910.146?a) 10%b) 19.5%c) 20.9%d) 23.5%e) None of the above
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PRE-INVENTORY5. According to the Permit-Required Confined
Space standard, no permit is required when the space is unsafe.
True False
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Lessons LearnedCSB Report – June 2007
Lack of hot work safety– Failure to recognize the hazards - use of
welding tools in a flammable vapor environment
– Failure to isolate fuel and ignition sources– Failure to manage hazards with well-
established, safe work practices (API, NFPA, OSHA)
Makeshift work platformSafe hot work guidelines
– NO permit issued
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HawaiiOctober 17, 2008Welding part of a catwalk connected to
the top of an oil storage tankTank was approximately 15 feet tall and
reportedly contained waste oilVapors from the tank were ignited by the
welding activities and caused the explosion that propelled tank 30 feet
One fatality, 3 injured, 2 seriously
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OhioOctober 20, 2008Welding catwalk on one of four large
crude-oil storage tanks at drill rig site when a tank exploded
Two fatalitiesCSB sent investigative team
– Looking for similarities with Hawaii and Mississippi
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RECOGNITION“Hazard Identification & Risk Assessment”
Identification of Spaces According to Definition
Identification of HazardsAtmospheric (oxygen, flammability, toxicity)EngulfmentEntrapmentOther physical or mechanical (energy sources,
heat stress, noise)
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EVALUATION“Confirm or Deny Presence of Hazards and Determine Severity”
Qualitative AssessmentUse MSDS, other reference sources, and
senses (subjective)Quantitative Assessment
Measurement of atmospheric components; compare test results to established standards to determine whether a safe condition exists (objective)
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CONTROL“Action taken to eliminate or minimize hazards”
EngineeringVentilationIsolationSubstitution
AdministrativeSafe Work PracticesPermitsTraining
Personal ProtectiveProtective ClothingRespiratory
ProtectionFollow-up
atmospheric monitoring
Emergency and rescue
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OSHA Points to MC for CS Evaluation – 1910.146, Appendix BAtmospheric testing is required for two distinct purposes:
evaluation of the hazards of the permit space and verification that acceptable entry conditions for entry into that space exist.
Evaluation testing. The atmosphere of a confined space should be analyzed using equipment of sufficient sensitivity and specificity to identify and evaluate any hazardous atmospheres that may exist or arise, so that appropriate permit entry procedures can be developed and acceptable entry conditions stipulated for that space. Evaluation and interpretation of these data, and development of the entry procedure, should be done by, or reviewed by, a technically qualified professional (e.g., OSHA consultation service, or certified industrial hygienist, registered safety engineer, certified safety professional, certified marine chemist, etc.) based on evaluation of all serious hazards.
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OSHA DEFINITION29 CFR 1910.146A confined space must have these characteristics:
Large enough and so configured to permit entry and work
Not designed for continuous human occupancy
Limited or restricted means of entry and exit
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PERMIT-REQUIRED CONFINED SPACE (PRCS)
Is a confined space that contains or may contain:
Hazardous atmosphere (oxygen content, flammable, or toxic)
Engulfment hazardEntrapment hazardOther recognized serious safety
hazard
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CONFINED SPACE EXAMPLESAboveground
and underground storage tanks
Process vesselsGrain silosBins
HoppersSewersUtility vaultsTanks on marine
vessels
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PRCS PROGRAM REQUIREMENTSWritten programIdentify and classify spacesEstablish hazard control measures
Prevent unauthorized entryEstablish acceptable conditionsIsolationVentilationCoordinate entry by multiple workersPeriodic reevaluation for change of conditions
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PRCS PROGRAM REQUIREMENTSDevelop permit system
PreparationIssuanceImplementationCancellationReturning space to service
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PRCS PROGRAM REQUIREMENTSProvide specialized equipment
Atmospheric monitoringVentilationPPELightingCommunicationEmergency
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PRCS PROGRAM REQUIREMENTSDesignate key personnel
EntrantsAttendantsEntry supervisorQualified atmospheric testerEmergency response
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PRCS PROGRAM REQUIREMENTSPerform testing and monitoring
Prior to entry and periodically during entry and work
Establish rescue and emergency procedures
Procedures for contractors - multi-employer work sites
Provide information and trainingConduct program review
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Confined Space ClassificationsNon-Permit Required Confined Space (API & OSHA)
Permit Required Confined Space (API & OSHA)
Non-Confined Space (API)
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Non-Permit Required Confined SpaceRemember what a confined space is!
Large enough and so configured to permit entry and work
Limited or restricted entry or exitNot designed for continuous occupancy
Non-permit means the confined space has no identified hazards
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Permit-Required Confined SpaceAll characteristics of confined space
as definedPossesses one or more identified
hazardsHazardous AtmosphereEngulfment hazardEntrapment hazardOther serious recognized hazard
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Hazardous AtmosphereExpose employees to –
Risk of deathIncapacitationImpairment of ability to self-rescueInjuryAcute illness
As a result of exposure to –
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Hazardous Atmosphere CriteriaFlammable gas, vapor, mist in excess of 10%
of lower flammable limit (LFL)Airborne combustible dust at its LFL **Oxygen concentration less than 19.5% and
greater than 23.5% by volumeToxic exposures in excess of PEL as found in
Subpart G or Subpart ZAny IDLH concentrationsContains or potential, serious harm
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DESIGNATED PERSONNEL - EntrantTrained to recognize hazardsTrained to use PPE as requiredCommunicate with attendant as
necessaryRecognize symptoms of exposureUnderstand principles of self-rescue
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DESIGNATED PERSONNEL - AttendantRemain outside space at all timesTrained to recognize hazards and exposure
symptomsCommunicate with entrantsCommunicate alarm, evacuate if necessaryMay monitor more than one space at a timePrevent unauthorized entrantsAlert to changing conditions
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DESIGNATED PERSONNEL – Entry SupervisorTrained to recognize hazardsAuthorizes entry based upon hazard
assessment, identify acceptable conditions
Verify emergency plans and rescue personnel availability
Revoke permit if conditions change adversely
Terminate permit at job completion
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DESIGNATED PERSONNEL - Qualified Atmospheric TesterResponsible for conducting
atmospheric monitoringTrained to properly select, calibrate,
use and maintain all required instruments
May be any of the key personnel - entrant, attendant, supervisor
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DESIGNATED PERSONNEL - Rescue and Emergency ServicesEither on-site or off-site permittedTrained at least as entrants and in
use of rescue equipmentTrained in basic first-aid/CPR and at
least one member certified in bothConduct annual drillCoordination between employer and
off-site provider
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ANSI/API 2015 – SummaryScope and Applicability
Applies to atmospheric and low-pressure aboveground petroleum storage tanks
Includes decommissioning, hazard assessment, permit entry and work system, emergency planning, and recommissioning
Does not apply to pressure vessels, process vessels, underground storage tanks
Industry specific application of OSHA requirements in 29 CFR 1910.146
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Testing the Tank Atmosphere
Determine what atmospheric hazards to test for based upon MSDS or other source
Determine safe exposure limitsDevelop written calibration
requirementsMaintain verification of calibration for 1
yearCalibrate according to manufacturer
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Atmospheric TestingTest in specific orderTest from outside tank initiallyTest atmosphere outside the tank as well
Especially during degassingShut down ventilation prior to testing
Rule of thumb 10 – 15 minutesConduct periodic or continuous
monitoringSpecialized testing – lead-in-air
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Storage Tank Hazards
Oxygen contentFire and explosionsToxic substances
Hydrogen sulfideOrganic LeadInorganic LeadAromaticsNORMOther
Physical and other hazardsTank function or
designTank conditionTank locationPhysiological
hazards (heat stress or cold stress)
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API RP 2016 – SummaryTank Entry Supervisors will have the
understanding, knowledge and skills to implement the specific tank cleaning procedures and practices presented in API 2016 in order to meet the requirements of ANSI/API 2015
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Tank Entry DesignationsEnter Without RestrictionsEnter With RestrictionsEnter With Special Precautions
Entry When Inerted (See API 2217A)
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Enter Without RestrictionsOxygen content – 19.5% to 23.5% by
volumeHydrocarbon vapor-in-air level
inside the tank is 10% LEL or lessAtmospheric toxic levels inside the
tank are within established exposure limits (PEL or TLV)
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Enter With RestrictionsThe actual or potential atmospheric
concentration levels require appropriate protective equipment or adjusted time
Review NFPA 326, Standard for the Safeguarding of Tanks and Containers for Entry, Cleaning, or RepairSimilar designation
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Enter With Special PrecautionsThis designation applies when:
Oxygen content inside the tank is < 19.5% by volume
Hydrocarbon vapor-in-air level inside the tank is > 10% LEL
Atmospheric toxic levels inside the tank exceed the established exposure limits (PEL or TLV)
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Entry When InertedThe oxygen content within the tank is less
than 8% by volume (or less than 50% of the lowest oxygen concentration level required to support combustion – Limiting Oxidant Concentration (LOC))NFPA 69, Standard on Explosion Prevention
Systems contains values for LOC
Becomes an Enter With Special Precautions
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Non-Confined SpaceDoes not meet any conditions necessary to
be considered a confined spaceAtmospheric conditions same as ambientNo restrictions on entry or exitTank has been isolated
See provisions in OSHA 29 CFR 1910.146 (c)(7) concerning reclassification
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Example of non-confined space – one that could be reclassified by 1910.146(c)(7)
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API Tank Entry Supervisor Certification (TES)Objective:
Enhance the quality and competency of tank entry and maintenance activities
Minimize the risks of confined space hazards
Improve the overall safety performance of tank maintenance operations
Process – combination of experience and examination
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Project Planning
Scope of Work & Site PlanMaterials & Equipment InformationSafety & Emergency ResponsePersonnel Qualification & TrainingClassification & Work PermitsHazards – Hazard CommunicationTank Information
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Tank Preparation
Facility Permits & Work OrdersPosition EquipmentRemove Recoverable ProductIsolate TankPosition, Bond & Start EductorOpen Manway & Remove Remaining
Product
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Ventilation and Atmospheric Testing
Identify supervisors & workersVentilate TankConduct External Atmospheric TestingContinue Ventilation & RetestIssue Permits for Internal Testing
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Enter to Visually Inspect and Evaluate
Assess, Identify & Address HazardsImplement CS Entry Program &
Emergency Response ProgramTest & Obtain Permits to EnterPerform Pre-Clean Safety InspectionVerify or Revise Scope of WorkCertify Tank Safe to Enter
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Clean Tank
Implement Cleaning Plan & PermitsMaintain Ventilation & TestingIdentify & Address Special HazardsMonitor Activities & SecurityCancel Permits, Stop Work & Exit Tank if
Conditions ChangeVerify Completion of Cleaning
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Entry for Repair
Implement Work & CS Entry PlansIdentify, Address & Monitor HazardsDetermine Classification of TankSupervise & Monitor Work ActivityMaintain Site & Tank Security Cancel Permits, Stop Work, Exit and Safe
tank if Conditions Change
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Return to Service
Inspect Tank Before ClosingVerify Recommissioned as PlannedAddress Tank ChangesSecure Tank & Clean AreaConduct Post-Entry Briefing
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API RP 2009, Safe Welding, Cutting and Hot Work Practices
Scope– Provide guidelines for safely conducting
welding, cutting and other hot work activities in the petroleum and petrochemical industries Hot tapping is excluded and covered by API RP
2201
Hot work defined as any operation that can produce sufficient heat, flame, spark or other source of ignition with the energy to ignite flammable gas, vapor or dust
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API RP 2009Job analysisHazard evaluation
and risk reductionImplementation of
safeguardsTesting for hazardsHot work permits
Hot work in confined spaces
Work inside vesselsWork on exteriorWork on equipment
in serviceWork in buildings
and pitsWork on piping
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NFPA 326, Standard for the Safeguarding of Tanks and Containers for Entry, Cleaning, or Repair Chapter 4 – Basic PrecautionsChapter 5 – Preparation for SafeguardingChapter 6 – Testing ProceduresChapter 7 – Control or Removal of VaporsChapter 8 – Inspection and Certification of
Tanks and ContainersChapter 9 – Procedures for Access to and
Entry of TanksChapter 10 – Cleaning Tanks and
Containers
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NFPA 326 PurposeEstablishes minimum requirements for the safe
opening, entry, and cleaning of a tank or container that contains or has contained flammable, combustible, or other hazardous substance vapors, liquids, or solid residues
…the safe removal of flammable, combustible, or other hazardous substance vapors, liquids, or solid residues from tanks or containers and the safeguarding of these vessels for entry, cleaning, or repair
…the minimum procedures that permit repair, hot work, or other operations that have the potential to create a fire, an explosion, or another hazard
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Chapter 6 – Testing ProceduresSafe entry, cleaning, or repair work
requires tests for oxygen, flammable/combustible, or other hazardous substance vapors, with an appropriate instrument:Before entry or re-entryBefore start of alterations or repairsBefore and during any hot work operationsContinuously or periodically during the workAfter cleaning tanks to determine that cleaning is
effectiveAfter any process or activity that might change conditions
Precautions also taken to ensure that tanks or containers that have held liquids with high flash points do not become hazardous during cutting and welding operations
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Chapter 8 – Inspection and Certification of Tanks and Containers
8.2.4 Hot Work AllowedEstablishes atmospheric thresholds
Oxygen enrichment – less than 23.5 % oxygenFlammable/combustible atmospheres – 0 % LFL
Residues – removed sufficiently to prevent regeneration of dangerous concentrations of contaminants
Adjacent spaces highlighted (as applicable)
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NFPA Safe Tank Entry Training - SummaryEstablish safe work practices based on
recognition, evaluation, and control principlesRecognize hazards inherent to space design as
well as use or functionRecognize that work can change initial
conditionsPerform frequent atmospheric monitoringUse forced mechanical ventilationEstablish permit systemTrain on safe work practices
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Role for the Marine Chemist with ASTMight not always be called to establish initial
entryRole of the attendant – frequent retesting of
conditionsHot workAtmospheric monitoring expertise –
especially for toxicityRecognized within the
petroleum/petrochemical AST environment
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OSHA Standards 1910.146 - Permit-Required Confined
Spaces 1910.106 - Flammable and
Combustible Liquids 1910.134 - Respiratory Protection 1910.147 - Control of Hazardous
Energy 1910.1000 - Air Contaminants 1910.1200 - Hazard Communications
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NFPA Codes & StandardsNFPA 30, Flammable and
Combustible Liquids CodeNFPA 326, Safeguarding Tanks or
Containers for Entry, Cleaning or Repair
Related informational documents –NFPA 306, Control of Gas Hazards on
VesselsNFPA 69, Explosion Prevention Systems
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Key API Standards & Recommended PracticesANSI/API Standard 2015, Safe Entry and
Cleaning of Petroleum Storage Tanks, 6th Edition (2001)
ANSI/API Recommended Practice 2016, Recommended Practice for Entering and Cleaning Petroleum Storage Tanks, 1st Edition (2001)
API Publication 2217A, Guidelines for Work in Inert Confined Spaces in the Petroleum Industry, 2nd Edition (1997)
API Publication 2219, Safe Operation of Vacuum Trucks in Petroleum Service, 2nd Edition (1999)
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Informational API Standards & Recommended Practices – Part IAPI Standard 653, Tank Inspection, Repair,
Alteration, and Reconstruction (2001)API RP 2003, Protection Against Ignitions
Arising out of Static, Lightning and Stray Currents (1998)
API Publication 2009, Safe Welding, Cutting and Other Hot Work Practices in Refineries, Gas Plants and Petrochemical Plants (2002)
API Publication 2026, Safe Access/Egress Involving Floating Roofs of Storage Tanks in Petroleum Service (1998)
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Informational API Documents – Part IIAPI RP 2027, Ignition Hazards and Safe
Practices for Abrasive Blasting in Atmospheric Storage Tanks in Hydrocarbon Service (2002)
API Publication 2201, Procedures for Welding or Hot Tapping on Equipment in Service (1995)
API Publication 2202, Dismantling and Disposing of Steel from Leaded Gasoline Aboveground Storage Tanks (1991)
API Publication 2207, Preparing Tank Bottoms for Hot Work (1998)
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Informational API Documents – Part IIIAPI Publication 2220, Improving Owner and
Contractor Safety Performance (1998)API Publication 2221, Manager’s Guide to
Implementing a Contractor Safety Program (1996)
API Publication 2350, Overfill Protection for Storage Tanks in Petroleum Facilities (1996)