In this training session, we will discuss the hazards of flammable liquids, as well as the precautions required for working safely with them.

The Occupational Safety and Health Administration, or OSHA’s, Flammable Liquid Standard, 29 CFR 1910.106, regulates storage and handling of these liquids.

OSHA’s Hazard Communication Standard, 29 CFR 1910.1200, requires your employer to train you about flammable liquid hazards and the steps you must take to work safely with them.

Because flammable liquids can be so hazardous and can cause fires, explosions, injuries, and extensive damage to workplaces, you need to know how to work safely with them so that you can minimize risks and prevent accidents.

Session Objectives

The main objective of this session is to help you work more safely with flammable liquids. By the time the session is over, you should be able to:

• Understand what a flammable liquid is;
• Identify flammable liquid hazards;
• Take proper precautions when storing, dispensing, and handling flammable liquids;
• Prevent fires, explosions, and exposures; and
• Know what to do in an emergency involving flammable liquids.

How Much Do You Already Know?

Before we begin the session, let’s take a few minutes to see how much you already know about working safely with flammable liquids. Decide which of the following statements are true or false.

• Flammable liquids are hazardous only when you are actually working with them.
• The single most important piece of information about a flammable liquid is its flash point.
• An ignition source must be right next to a flammable liquid to cause the vapors to ignite.
• You might need to wear personal protective equipment, or PPE, when working with flammable liquids to avoid harmful exposures.
• If you are dispensing only a little flammable liquid, bonding and grounding are not necessary.

Did you get all the right answers? If so, you’re already well on your way to learning what you need to know about working safely with flammable liquids. If not, don’t worry. We’ll go over this information and a lot more during the session.

Why Is This Training Important?

Why is this training session important to your safety? Here are three good reasons. These are all true stories.

1. A violent explosion at a manufacturing facility destroyed the facility, heavily damaged dozens of nearby homes and businesses, injured 10 people, and caused the evacuation of more than 300 residents within a half-mile radius of the facility. The explosion was fueled by vapor released from a 2,000-gallon tank of highly flammable liquid. An unknown ignition source ignited the flammable atmosphere, causing the explosion.
2. A fire and explosion at a paint factory seriously injured three workers and damaged the factory. Components used in the mixture of the paints made at the factory were highly flammable. A static spark or even a hot lightbulb could have caused vapors to ignite.
3. A fire started when a 300-gallon portable steel tank was being filled with ethyl acetate, a flammable solvent, which spread rapidly, igniting a large volume of flammable liquids stored nearby. A plume of smoke and rocketing barrels and debris triggered an evacuation of the businesses surrounding the facility. The main warehouse structure was destroyed, but miraculously, no one was injured.

Which Statements Are True?

See if you know which of the following statements are true about flammable liquids.

• The vapor from flammable liquid ignites, not the liquid itself.
• Fires involving flammable liquids are difficult to put out and can spread quickly.
• Flammable liquids are common materials that are often used carelessly.
• Flammable vapors are heavier than air, so they can travel to an ignition source and flash back.

What Is a Flammable Liquid?

Before we go any further, let’s take a moment to make sure we’re all thinking about the same thing when we use the term “flammable liquid.”

• A “flammable liquid” is defined by OSHA as any liquid with a flash point at or below 199.4 degrees Fahrenheit or 93 degrees Celsius.
• “Flash point” means the minimum temperature at which a liquid gives off vapor within a test vessel in sufficient concentration to form an ignitable mixture with air near the surface of the liquid.

Examples of Flammable Liquids

Examples of flammable liquids include:

• Isopropyl alcohol;
• Propane;
• Solvents, such as acetone, MEK, paint thinner, and varnish; and
• Fuels, such as gasoline.

Hazards of Flammable Liquids

Now let’s take a look at what the hazards of flammable liquids are.

• The primary hazards of flammable liquids are fire and explosion.
• These liquids can vaporize and form flammable mixtures with air when:

– They are exposed to air, as when a container of the liquid is left open;

– Leaks or spills of the liquid occur; or

– The liquid is heated or aerosolized. “Aerosolized” means sprayed or otherwise dispersed in the air as particles.

• Some flammable liquids can be hazardous to health if vapors are inhaled or if the liquid splashes in eyes or gets absorbed by the skin.

Degree of Risk

The degree of risk of an explosion or fire is determined by:

• The flash point of the flammable liquid. A lower flash point means a greater risk of fire or explosion;
• The vapor’s concentration in the air—the higher the concentration, the greater the hazard;
• The presence of potential ignition sources—more ignition sources in the area obviously mean a greater risk; and
• The potential for flashback. Since most flammable vapors are heavier than air, they can travel to a distant source of ignition and flash back.

Remember that it’s the vapors that actually catch fire or explode, not the liquid.

Flash Point

The flash point is the single most important piece of information you need to know about a flammable liquid.

• As we said earlier in this program, the flash point is the lowest temperature at which the liquid will give off enough vapors to be ignited.
• Also, as we said in the previous slide, a low flash point means high flammability. For example, a liquid with a flash point of 50 degrees Fahrenheit means that the vapors could easily ignite at a cool temperature. Gasoline, for example, has a relatively low flash point and can ignite even in cold temperatures.
• For flammable liquids, the flash point is at or below 199.4 degrees Fahrenheit or 93 degrees Celsius. This means that many flammable liquids give off enough vapors to be ignited at room temperature, and they give off more vapors when it’s warmer.
• The safety data sheet, or SDS, for a flammable liquid will identify the flash point for you.
• OSHA regulations categorize flammable liquids according to their flash points. Let’s go over more about classifications on the next screen.

Flammable Liquid Categories

According to OSHA’s Flammable Liquid Standard (29 CFR 1910.106), flammable liquids are divided into four categories as follows:

• Category 1 includes liquids having flash points below 73.4º Fahrenheit (23º Celsius) and having a boiling point at or below 95º Fahrenheit (35º Celsius).
• Category 2 includes liquids having flash points below 73.4º Fahrenheit (23º Celsius) and having a boiling point above 95º Fahrenheit (35º Celsius).
• Category 3 includes liquids having flash points at or above 73.4º Fahrenheit (23º Celsius) and at or below 140º Fahrenheit (60º Celsius). When a Category 3 liquid with a flash point at or above 100º Fahrenheit (37.8º Celsius) is heated for use to within 30º Fahrenheit (16.7º Celsius) of its flash point, it must be handled in accordance with the requirements for a Category 3 liquid with a flash point below 100º Fahrenheit (37.8º Celsius).
• Category 4 includes liquids having flash points above 140º Fahrenheit (60º Celsius) and at or below 199.4º Fahrenheit (93º Celsius). When a Category 4 flammable liquid is heated for use to within 30º Fahrenheit (16.7º Celsius) of its flash point, it must be handled in accordance with the requirements for a Category 3 liquid with a flash point at or above 100º Fahrenheit (37.8º Celsius).

NOTE: When liquid with a flash point greater than 199.4º Fahrenheit (93º Celsius) is heated for use to within 30º Fahrenheit (16.7º Celsius) of its flash point, it must be handled in accordance with the requirements for a Category 4 flammable liquid.

Flammable Range

Another important safety issue concerning flammable liquids is the flammable range.

• The “flammable range” is the range of concentrations of vapor or gas with air that will support burning, or combustion.
• Not all mixtures of vapor or gas and air will burn. Some mixtures are too lean, meaning not enough vapor or gas.
• Some mixtures are too rich, meaning too much vapor or gas mixed with air to burn.
• In order to burn, the vapor or gas/air ratio must be in the flammable range. The flammable range is the range between the Lower Explosive Limit, or LEL, of the substance, which is the point at which there is not enough vapor or gas in the air to burn, and the Upper Explosive Limit, or UEL, which is the point at which there is too much vapor or gas mixed with the air to burn.

Let’s Review Flash Points And Ranges

Now let’s quickly review what we’ve said about flash points and flammable ranges. See if you know the best answer to these questions:

• Is the flash point of flammable liquids—Above 199.4º Fahrenheit or Below 199.4º Fahrenheit?
• Where can you find the flash point of a flammable liquid—On the SDS or on the Label?
• What do you call the range of concentrations of fuel with air that will support burning—Flash point or Flammable range?
• What is the point in the flammable range in which there is not enough fuel in the air to burn—UEL or LEL?

Evaporation Rate

To prevent ignition of flammable vapors, you also need to know about a flammable liquid’s evaporation rate.

• The evaporation rate is the amount of time it takes for a liquid to change into a vapor.
• The higher the evaporation rate, the more quickly a flammable liquid will vaporize and thus present greater risk of fire and explosion.
• You can find the evaporation rate for specific flammable liquids in Section 9 of the SDS.

Measuring Flammable Vapors

You need to know if flammable vapors are present and in what concentration.

• Measuring whether there are enough flammable vapors to burn requires using a gas meter.
• Gas meters measure the vapor concentration in real time and provide a readout expressed as a percentage of the lower explosive limit.
• For example, a reading of 25 percent LEL means that the fuel-and-air mixture is 25 percent of the way to the lowest fuel concentration that can burn. That may seem very low, but in fact, a 25 percent reading is considered the point at which a flammable atmosphere may exist. That’s because the concentration may change, or may be higher at another point, or the meter may have underreported the concentration.
• Never enter an atmosphere that has a concentration of flammable vapors that is greater than 25 percent of LEL!

How Much Are You Learning?

Let’s see how much you’ve learned so far about flammable liquids. See if you know the correct word to complete each statement. Pick the best choice.

• Flammable liquids are fire hazards because the ___________ (liquid or vapors) can ignite and burn or explode.
• You can find important safety information about flash points and evaporation rates of flammable liquids in the ______________ (SDS or label).
• A low flash point means that a flammable liquid is _______________ (slightly or highly) flammable.
• “Flammable liquids” are defined as liquids with a flash point at or below __________ (199.4 or 50) degrees Fahrenheit.
• The primary hazard of flammable liquids is ____________ (illness or fire).

If you didn’t get all the right answers, you may want to go back and review before we move on to the second half of the session.

What Have You Learned?

Now it’s time to ask yourself if you understand the information presented so far. For example, do you understand what we’ve said about:

• Why this training is important?
• The definition of flammable liquid?
• Hazards of flammable liquids?
• Degree of risk?
• Flash point?
• Flammable range?
• Evaporation rate? And,
• Measuring flammable vapors?

It’s important to understand all this information so that you can work safely with flammable liquids. Now is a good time to take a few minutes to go back and review anything that isn’t clear if you need to. When you’re ready, you can continue to the next part of the session where we’ll talk about minimizing the risk of fire and explosions.

6 Basic Steps for Minimizing the Risk of Fire and Explosions

There are six basic steps you can take to minimize the risk of fire and explosions related to flammable liquids in the workplace:

1. Read warning signs, labels, and the SDS;
2. Store flammable liquids safely;
3. Handle flammable liquids properly;
4. Eliminate ignition sources;
5. Dispense them correctly; and
6. Minimize vapor concentrations.

In the next screens, we will review each of these essential safety precautions for working safely with flammable liquids.

Warning Signs

Warning signs are an important safety measure for preventing flammable liquid incidents.

• Warning signs identify areas where flammable liquids are stored, dispensed, and used.
• Always look for warning signs wherever you go in the facility.
• And, follow the instructions on warning signs.

Labels

Always read flammable liquid labels, and look for special warnings and safety and health information. Here is a quick review of what you will find on OSHA-required labels.

• Flammable liquid labels tell you what to do in case of fire involving the substance—for example what type of extinguishing device to use.
• Labels carry a signal word, such as “Danger” or “Caution,” which indicates the severity of the hazard. For many flammable liquids, the signal word will be “Danger.”
• OSHA-required labels also have hazard statements that describe the nature of the hazard, such as degree of flammability.
• Labels provide first-aid information that can help you act quickly and effectively in an emergency.
• Labels may also provide pictograms that convey specific hazard information using symbols or graphics.
• Precautionary statements describe recommended measures to minimize or prevent injury or illness due to exposure to the flammable liquid, or from improper handling or storage.

Label Examples

This is an example of a label required by OSHA’s Hazard Communication Standard.

• Alternative labels are permitted if they provide essentially the same information as OSHA labels. Here are two examples of alternative labels:
• The Department of Transportation, or DOT, also has labels for flammable liquids being transported by road, rail, or vessel. These placards provide only minimal information. They are meant to identify the liquid and its hazard level at a glance so that emergency responders will know the danger they face.

SDS

The SDS is your primary source for safety and health information about flammable liquids. The SDS provides the most complete information and includes much important data not found on labels. For example, the SDS will provide:

• Flash point, which as we said earlier is the single most important piece of information you need to know about flammable liquids;
• Special storage and handling precautions;
• Dispensing instructions, including using proper bonding and grounding techniques;
• The LEL and UEL, which we discussed in a previous screen;
• Reactivity hazards, describing the types of materials that the flammable liquid should not be stored with;
• Fire-fighting equipment and methods; and
• Hazardous combustion products, which are the hazardous gases or fumes given off when the flammable liquid is burning.

Safe Storage of Flammable Liquids

Safe storage practices for flammable liquids include:

• Do not use open flames, smoke, produce sparks, or weld in areas where flammable liquids are stored.
• Keep flammable liquids away from direct sunlight, and store in a cool, dry place.
• Make sure containers are properly closed to prevent vapors from escaping, and check regularly for leaks.
• Make sure storage areas are well ventilated to prevent vapors from building up. The vents should run from floor to ceiling.
• Store oxidizers and other incompatible materials at least 20 feet away from flammable liquids to prevent a dangerous reaction.
• Use secondary containment methods to make sure any spills are contained.
• And, return liquids to their storage location immediately after use.

Flammable Liquids Review

Let’s take a moment now for a quick review about working safely with flammable liquids. See if you know the best answer for each question.

• Which has the most complete safety and health information about flammable liquids—The label, The SDS, or Your coworkers?

– Labels have basic information, but the SDS provides the most complete information and, therefore, should be your primary source of information about flammable liquids. Always consult the SDS in addition to the label or coworkers.

• OSHA-required labels tell you—The nature of the hazard only, How to minimize risks only, or Both of these.

– OSHA-required labels have hazard warnings and pictograms that indicate the nature of the hazard. They also have precautionary statements that tell you how to minimize risks.

• The SDS provides information about safe—Storage only, Dispensing only, or Both of these.

– The SDS provides information about safe dispensing and storage, as well as safe handling instructions.

• Flammable liquids should be stored in areas away from—Humidity, Ignition sources, or Ventilation.

– Flammable liquids should be stored in well-ventilated areas away from ignition sources.

• Where is the best place to find the flash point of a flammable liquid—The label, The SDS, or Facebook?

– You will find the flash point in Section 9 of the SDS.

Dispensing Flammable Liquids Properly

Proper procedures must also be followed when dispensing flammable liquids to prevent accidents.

• Perform transfers of flammable liquids only in well-ventilated areas.
• Perform transfers away from all ignition sources.
• Ensure that the primary container or drum is properly bonded and grounded. Static electricity can build up between the primary container and smaller containers you are dispensing into. The bonding and grounding procedure prevents static electricity from igniting flammable vapors. More about bonding and grounding on the next screen.
• If you use a pump, transfer liquids with a hand pump. Use a motorized pump only if it is explosion-proof and grounded. Plastic pumps may also be used.
• Use only sparkproof tools, such as drum wrenches, around flammable liquids.

Bonding and Grounding

Bonding and grounding are effective techniques for reducing the likelihood of ignition of flammable liquids from static electricity while dispensing.

• Bonding involves electrically connecting a flammable liquid storage container to the dispensing container with a bonding cable and clip so that the containers have the same electrical potential. When liquids pass through air, such as when flammable liquids are poured or dispensed, they collect static electricity. Static sparking cannot take place if the objects have the same electrical potential.
• Grounding is another method for minimizing the risk of static sparking, possibly resulting in a fire. Grounding involves creating a low-resistance path to the ground. Usually, a flammable liquid storage container would be grounded by a wire connecting it to an electrode driven into the ground or connected to a building’s grounding system (for example, a metal pipe or I-beam). When properly done, electrical energy follows this path, thus preventing the buildup of static electricity that could otherwise result in ignition of flammable vapors. Grounding should be used in addition to bonding when dispensing flammable liquids.

Safe Handling of Flammable Liquids

Safe handling of flammable liquids prevents spills, fires, explosions, injuries, and harmful exposures. Here are some key safe-handling tips.

• Use only approved containers for small amounts of liquids. These should be fire-resistant safety containers with self-closing lids.
• Make sure these containers are properly labeled so that you and coworkers know what is in the container and the precautions that must be taken to prevent accidents.
• Close containers when not in use. This helps prevent flammable vapors from building up.
• Take only the amount of liquid you need for the job, and use it in well-ventilated areas to prevent buildup of vapors. Taking only the amount of liquid you need will help minimize any fires or spills if they do occur.
• Put rags soaked with flammable liquids in approved, closed containers. Dispose of unused flammable liquid wastes properly.
• Avoid mixing flammable liquids or mixing flammable liquids that have different flash points.
• Do not weld or torch-cut containers that once held flammable liquids. There may still be vapors in the drum that could ignite and cause an explosion.

Ignition Sources

See if you can identify all the potential ignition sources that could cause flammable liquid vapors to start burning or to explode. Decide which of these things on the screen is an ignition source.

• Here are the correct answers:

– Static electricity,

– Cigarettes,

– Welding equipment,

– Sparks,

– Electrical equipment, and

– Hot surfaces.

Did you get them all?

Vapor Control

Controlling flammable vapors is an important way to prevent fires and explosions. For example, you can:

• Control temperatures to minimize the formation of vapors;
• Use proper ventilation to remove vapors from the work area atmosphere;
• Use closed systems to keep vapors from getting into the general work area atmosphere; and
• Keep containers closed when not in use to prevent vapors from mixing with air.

PPE

Since many flammable liquids can be hazardous to your health, PPE is often necessary to prevent harmful exposures. For example, when working with flammable liquids, you may be required to wear:

• Goggles to protect your eyes;
• Gloves and body protection, such as coveralls, to prevent absorption of liquids through your skin; and
• A respirator to prevent inhalation of hazardous vapors.

Emergency Response for Fires

Flammable liquid fires are extremely dangerous. They can spread quickly, and the potential for explosion often exists. When responding to fires involving flammable liquids:

• Remove yourself from danger and notify other workers in the area;
• Report the fire, following proper emergency procedures; and
• Evacuate the area unless trained and authorized to fight fires involving flammable liquids.

Emergency Response for Spills

When responding to spills involving flammable liquids:

• Report all spills of flammable liquids immediately.
• Follow spill response procedures required by workplace safety rules.
• Clean up small spills if you are authorized, and dispose of cleanup materials and any liquids properly. Be sure to use appropriate PPE when cleaning up spills.
• Do not try to clean up large spills yourself. Larger spills require a specially trained and equipped spill response team.
• Eliminate all ignition sources in the area: cigarettes, welding operations, machinery, and electric equipment.
• Evacuate the area to a safe distance.
• And finally, help in the cleanup of a large spill only if you are properly trained, equipped, and authorized.

First Aid

Common first-aid procedures for exposure to flammable liquids include:

• For inhalation of flammable liquid vapors, move into fresh air until symptoms of exposure go away. Get medical assistance if symptoms get worse or persist.
• For splashes of flammable liquid in your eyes or face, flush your eyes or face at a designated eyewash station for 15 minutes.
• For other skin contact with a flammable liquid, wash with soap and water.
• For ingestion (swallowing) of a flammable liquid, consult the SDS and call a doctor. Different hazardous materials call for different types of treatment if ingested.

IMPORTANT: Always read the container label or SDS to make sure you are using the right first-aid methods.

What Have You Learned?

Decide whether each of the statements on the screen is true or false.

• Flammable liquids can travel to a distant source of ignition and flash back.
• Flammable liquid vapors can ignite and explode.
• When dispensing flammable liquids, you should bond and ground containers.
• The higher the evaporation rate of a flammable liquid, the less likely it is to catch fire.
• Fires involving flammable liquids are easy to put out.

How did you do? If you missed any of the answers, now is a good time to go back and review before we finish up with a review and key points to remember.

Review

Now let’s take a few moments to review the information presented in the previous slides. Did you understand what we said about:

• Warning signs, labels, and SDSs?
• Safe storage, dispensing, and handling of flammable liquids?
• Ignition sources?
• Vapor control?
• PPE? And,
• Emergency response?

You should understand all this information so that you can prevent fires, explosions, and harmful exposures involving flammable liquids.

If you need to go back and review anything that isn’t perfectly clear, now is a good time to do that.

Key Points to Remember

Here are the main points to remember about this training session on working safely with flammable liquids:

• Flammable liquids can ignite with explosive force.
• Keep these liquids away from all ignition sources.
• Follow proper storage, dispensing, and handling procedures.
• Use only approved containers that are properly labeled.
• Review the label and SDS for safety and health information about the flammable liquids you work with.

This concludes the Working Safely with Flammable Liquids training program.