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Published byLawrence Rose Modified over 8 years ago
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The Shepherd Chemical Company Lisa Thamann 11/12/2013 AMMONIUM NITRATE A New Understanding
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OVERVIEW Background Original State Process Hazard Analysis Applicable Code Review Current State Lessons Learned NH 4 NO 3
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BACKGROUND Schedule of PHAs conducted annually Ammonium Nitrate was not on the 2013 schedule West, TX incident on 4/17/2013 Address management and employee concerns
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ORIGINAL STATE Main Raw Material Storage Up to 60,000 lbs. of Ammonium Nitrate Prill Secured Entry Shared Storage Satellite Storage Four locations in plant Up to 2000 lbs. Open piece bags Limited Security
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ORIGINAL STATE
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PROCESS HAZARD ANALYSIS Systematic approach to assess the potential hazards of a process using a defined methodology Methodology: What If Analysis Creative brainstorming methodology Process is broken up into nodes Nodes are organized around major pieces of process equipment or systems Rank each risk based on two parameters Severity Likelihood
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PHA GOALS Identify potential hazards/risks and their impact on: Health & Safety of personnel Environment Community Regulatory Requirements Recommend actions to drive risk down Prioritize recommendations Based on Risk Ranking Document safe operating limits
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NON-TRADITIONAL PHA: Code Comparison NH 4 NO 3 Storage & Handling o Receiving o Bulk Storage o Distribution o Satellite Storage
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APPLICABLE CODE REVIEW Applicable Codes: OSHA 1910.109(i): Storage of Ammonium Nitrate NFPA 400: Hazardous Materials Code Chapters 1-6: General Definitions, Classifications & Requirements Chapter 11: Ammonium Nitrate Solids & Liquids
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APPLICABLE CODE REVIEW Maximum Allowable Quantity OSHA 1910.109(i): >1000 lbs. NFPA 400: Depends Oxidizer Classification Unstable Reactive Classification
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NFPA CLASSIFICATIONS CLASSOXIDIZERUNSTABLE REACTIVE 1Does not moderately increase the burning rate of combustible materials Normally stable but could become unstable at elevated T & P 2Causes a moderate increase in burning rate of combustible materials Materials that readily undergo violent chemical change at elevated T & P 3Causes a severe increase in burning rate of combustible materials Materials that in themselves are capable of detonation, explosive decomposition or explosive reaction, but require a strong initiating source, heat & confinement before initiation 4Class 3 plus can undergo an explosive reaction from contamination or exposure to thermal/physical shock. Materials that in themselves are readily capable of detonation, explosive decomposition or explosive reaction at normal T & P
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NFPA 400 MAQ Class 3 Oxidizer, Class 3 Unstable Reactive 10 lbs. Protection Level: 2 MAQ can be increased to 550 lbs. if the following requirements are met: < 200 lbs./ft 2 < 6 feet high < 100 lbs. per container Noncombustible floors Incompatibles at least 30 feet away Hazard identification per code 4 foot aisles If fire suppression meets NFPA 13 MAQ can be doubled to 1100 lbs.
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COMMON REQUIREMENTS Storage approval from area of jurisdiction No basement One story building 30 feet from incompatible materials Adequate ventilation Automatic sprinklers system designed per NFPA 13 ≥ 1-hr fire resistive walls Noncombustible flooring < 130 ° F At least 3 foot aisles 30 inches from wall Can’t be stacked 3 feet from roof Dry and free of water intrusion Controlled access
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OTHER NFPA 400 REQUIREMENTS Specific Training Physical & Health Properties Emergency Response Storage Transporting Labeling Egress Secondary Containment Spill Control Plan Security Plan
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Detached Building Requirement Class 3 Unstable Reactive 1 ton or less on site 40,000- 60,000 lbs. At least 2000 feet away from inhabited buildings for un- barricaded storage OR At least 1300-1600 feet away from inhabited buildings for barricaded storage
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PHA OUTCOME 38 Recommendations Adequate storage location Upgrade storage facility to meet applicable codes Reduce MAQ Incompatible materials Improved training Labeling Security Disposal Hot work practices Containment
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TODAY Drastically reduced onsite storage to 4,400 lbs. Worked with supplier to provide weekly deliveries A maximum of 1100 lbs. is kept in each control area Implemented rated storage cages with secondary containment Separated incompatibles Monthly reconciliation & tighter security Improved training & hazard communication Opportunities to use liquid ammonium nitrate
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TODAY
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LESSONS LEARNED NFPA provides an excellent resource to aid in code applicability Actual hazards of bulk ammonium nitrate storage Improve site-wide awareness of ammonium nitrate storage and incompatibilities OSHA vs. NFPA Strive to implement best practices
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LESSONS LEARNED The ability and necessity to act quickly to address high hazard concerns Shepherd Chemical’s commitment to the safety of our employees and the community
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