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The HFSP training manual

1. Introduction, course overview and objectives

2. History and legislative context

3. HFSP overview

4. How is the HFSP integrated into district plans?

5. When a resource consent is required for a hazardous facility

6. Classifying and rating hazardous substances for the HFSP

7. Using the HFSP – a step by step guide

8. Case studies

9. HFSP workbook and spreadsheet

10. Implementing the HFSP

Module 7: Using the HFSP – a step by step guide

What, why and how|Overview of the steps required to carry out the HFSP|Some important things to know|Possible shortcuts|Step by step guide to the HFSP|Case study

What, why and how

What

• overview of the steps required to carry out the HFSP
• a discussion of specific points to note
• a discussion of possible shortcuts

Why

• to understand and apply the logical sequence of steps of the HSFP
• to highlight some areas requiring attention· to learn how to apply relevant shortcuts

How

• presentation
• exercise and report in

Overview of the steps required to carry out the HFSP

Overview

An overview of the key building blocks of the HFSP was provided in Module 3.

When starting to work with the HFSP, it is recommended that a set of logical steps be followed. These steps have been described in detail in the Land Use Planning Guide for Hazardous Facilities (MfE, 2002). These steps are summarised in Figure 7.1 and described in detail in Table 7.1.

The steps have been designed so that all the necessary information is gathered and in the right format, and that the calculations are carried out in the right sequence. A worksheet has also been developed to make this process easier. This is attached inTable 7.2.

Also attached again are the tables containing the Base Quantities and the Adjustment Factors (Tables 7.3 and 7.4).

Some important things to know

Units and Conversions

The HFSP uses the standard units of tonnes (for solids, liquids, and liquefied gases), and m³ (for compressed gases). It is therefore sometimes necessary to convert hazardous substances quantities to these units.

For this purpose, it is therefore necessary to remember that units for liquids (litres or m³) are converted to weight (kilograms or tonnes) through multiplication with the specific gravity or density

Example: Petrol has a specific gravity of 0.74. Therefore, 10,000 litres of petrol equate to: 10,000 x 0.74 = 7,400 kg or 7.4 tonnes.

Diluted or mixed substances

Conversions of quantities are also required when a substance is diluted or mixed with another substance. In this instance, only the percentage of the pure substance in the dilution or mixture is accounted for.

For example, 1,000 litres of a 30% solution equates to 0.3 tonnes or 300 kilograms of the pure substance (assuming the specific gravity is about 1).

HSNO/UN Classifications sometimes apply to specific commercial strength substances

Some substances are commercially traded and transported as dilutions of the full strength hazardous substance. As a result, the HSNO/UN Classification may sometimes be applied to a specific commercial strength solution. Examples of this are commercial solutions of corrosives, oxidisers and pesticides. In these instances, conversions are only applied if these commercial strength solutions are further diluted.

Small packages vs bulk quantities

The HFSP treats small packages in the same way as bulk quantities. Even though small containers reduce the risk of a major spill, they may still react like bulk quantities in some emergencies.

Storage vs use

In some cases, it is difficult to assess whether a particular activity constitutes a storage or a use. Generally, the HFSP considers a substance in use when the full amount of the substances is used at any time. An example of this is acid baths in an eletroplating business.

Possible shortcuts

Selection of priority substances

There are a number of shortcuts one can take to make the use of the HFSP easier.

Often, numerous substances may be handled at one site, and it is neither necessary nor practical to apply the HFSP to all substances. The “common sense” guideline is to initially assess only those substances that occur in the greatest quantities or are known to be most hazardous, as often one substance alone may trigger the need for a consent.

This means that the primary purpose of the HFSP, that is, to screen an application to determine whether a resource consent is required, has already been achieved.

Another alternative is to assess a substance only in terms of only one of the Effect Groups, if this happens to be the critical one that may determine the need for a resource consent.

It pays therefore to scan an application and pick out those substances first that either are the most hazardous and/or occur in the greatest quantities.

Precautionary Approach

Sometimes, either the information or the time (or both) are lacking to carry out a comprehensive classification and assessment of a particular hazardous substance. Shortfalls of information often occur in the environmental area, whereas either very flammable or toxic substances are normally well covered.

In such an instance, the precautionary approach is appropriate (refer Module 6), with Hazard Levels assigned as follows:

• Fire/Explosion Effects Group: MEDIUM Hazard Level
• Human Health Effects Group: MEDIUM Hazard Level
• Environmental Effects Group: HIGH Hazard Level

Assigning such precautionary hazard levels may also be appropriate if a quick check of a facility is required.

It is only when the results are quite marginal or close to the trigger levels in the consent status matrix in the district plan, that additional data will have to be gathered to ensure the necessary accuracy of the calculations.

Step by step guide to the HFSP

Step 1

Describe the hazardous facility

Prior to using the HFSP, it is necessary to compile a full description of the hazardous facility in question. This includes the creation of an inventory of hazardous substances held on the site, including:

• names of the hazardous substances
• quantities of the hazardous substances
• the physical form of the substances at 20oC and 101.3 kPa
• the location of use or storage on the site, including separation distances from the site boundary and neighbouring hazardous facilities (on-site and off-site).

The description should also include site-specific details, including neighbouring land uses and the surrounding environment, with a focus on sensitive land uses and receptors (eg, retirement accommodation, aquifers or wetlands).

HFSP Calulations and example

Explanation

The HFSP uses standard units of tonnes (t) (for solids, liquids and liquefied gases) and cubic metres (m³) (for compressed gases). In some cases, it may therefore be necessary to convert substance quantities to these units. In the case of liquids, specific gravity (or density) must be taken into consideration when converting litres or (m³) to tonnes (ie,

volume of liquid (litres) x specific gravity = tonnes).
1000

Adjustments to quantities are also necessary where a substance is diluted with water or mixed with another substance. In this instance, only the percentage quantity of the hazardous substance or product in the dilution or mixture is assessed for the purposes of HFSP calculations (unless a mixture is more hazardous than its components, in which case data on the mixture need to be used).

An exception to this are products or brands that already constitute dilutions or mixtures of hazardous substances and which have been classified in terms of their hazardous properties as the ‘whole’ dilution or mixture for life cycle management purposes. Examples of this are corrosives, oxidising substances and pesticides, which are often sold commercially as standard solutions or strengths. In these cases, quantity adjustments are only applied when these commercially supplied concentrations are further diluted or mixed.

Step 2

Determine Hazard Rating

For the purposes of the HFSP, the effects of substances are categorised into three Effect Types:

• Fire/Explosion Effect Type: addressing damage to the built environment and safety of people;
• Human Health Effect Type: addressing adverse effects on the well-being, health and safety of people;
• Environmental Effect Type: addressing adverse effects on ecosystems and natural resources.

Each Effect Type is divided into three Hazard Rating Levels:

• High
• Medium
• Low

The rating levels are based predominantly on the HSNO classification system.

HFSP Calulations and example

Explanation

The HFSP rates hazardous substances in terms of each of the three Effect Types as having a high, medium or low hazard. The Hazard Rating of a substance is derived from:

1. The list of HFSP-rated hazardous substances in Appendix B of the Red Book.
2. The HSNO classification (refer Appendix A of the Red Book). Once a substance has been classified under HSNO, Hazard Ratings can be assigned for each Effect Type as shown in Appendix A of the Red Book.
3. Where a substance is neither found in Appendix B of the Red Book nor the HSNO databases on the MfE/ERMA websites, default ratings should be used (Fire/Explosion Effect Type: Medium, Human Health Effect Type: Medium and Environment Effect Type: High)

Step 3

Determine Hazard Rating

Find Base Quantities

The Base Quantity (B) is pre-calibrated. It is the amount of a substance that has been assessed as generating no significant off-site effects in a heavy industrial area before site- and substance-specific considerations have been taken into account (refer Step 4). Base Quantities for different hazardous properties and hazard ratings in each Effect Type are listed in Table 3.1.

HFSP Calulations and example

Explanation

For example, in the Fire/Explosion Effect Type [Sub-category Flammables], non-significant off-site effects in a heavy industrial area are represented by a Base Quantity of:

• 100 tonnes of a HSNO Category D flammable liquid which has a low hazard level for the Fire/Explosion Effect Type.
• 30 tonnes of a HSNO Category C flammable liquid which has a medium hazard level for the Fire/Explosion Effect Type.

Step 4

Calculate Adjusted Quantity (A)

The pre-calibrated Adjustment Factors (FF, HF, EF) are multiplied with the Base Quantities (B) to account for substance properties and site-specific environmental circumstances. This multiplication yields the Adjusted Quantity (A).

Adjustment Factors differ for each of the Effect Types, and take into account the following considerations:

• the physical state of the substance
• the type of storage
• the type of activity or use
• separation distances to the site boundary
• the environmental sensitivity of the site location.

The Adjustment Factors are listed in Table 4.

HFSP Calulations and example

Explanation

Different Adjustment Factors are applied for each Effect Type. For example, for the Fire/Explosion Effect Type, the temperature is relevant, while for the Human Health Effect Type, proximity to a potable water resource is important.

In some instances, more than one Adjustment Factor within each Effect Type must be applied, which then need to be multiplied with each other to yield the total Adjustment Factor for the Effect Type. When the Adjustment Factors for each Effect Type have been calculated, they in turn are multiplied with the Base Quantity to yield the Adjusted Quantity).

In the example given, the following parameters have been assumed:

• <30m to site boundary
• not adjacent to water body
• underground storage.

Step 5

Calculate and add Quantiy Ratios (FQ, HQ, EQ)

This step requires the calculation of the Quantity Ratio for each hazardous substance in question. The Quantity Ratio is a dimensionless number. It is obtained by dividing the quantity of a substance that is proposed to be used or stored on a site, ie the Proposed Quantity (P) by the Adjusted Quantity (A).

If several hazardous substances are used or stored on a site, the Quantity Ratios calculated for each of these substances are added up for each Effect Type.

Note that FQ/HQ/EQTotal stands for the total sum of Quantity Ratio values from all assessed hazardous substances, within each Effect Type.

HFSP Calculations

By using the dimensionless ratio of the Proposed Quantity of a hazardous substance over the Adjusted Quantity, it is possible to aggregate the effects presented by multiple substances held on the same site. Hence, it becomes possible to assess the cumulative potential effects which may be created by several substances present on the same site.

Step 6

Assess resource consent status of hazardous facility

When assessing the resource consent status of a particular hazardous facility, the added Quantity Ratios for each Effect Type are compared with relevant Consent Status Indices in the Resource Consent Matrix in the district plan. If they are exceeded, a resource consent is required.

HFSP Calculations

Explanation

When examining total Quantity Ratios against applicable Consent Status Indices, one or several substances may trigger a resource consent. This highlights the fact that when assessing hazardous facilities, it is often sufficient to assess just a few hazardous substances to start off with, mainly those that are either highly hazardous or are used/stored in high quantities.

Exercise 7.1

a) Review the attached case study by following the outlined steps. Please answer the following questions.

• How does one convert a liquid unit (for example, litres or m3) to a solid unit (i.e., kg or tonnes)?
• When is it necessary to make an adjustment for a diluted quantity?
• Was it necessary to assess all the substances in this case study?
• Which one was the key substance that determined the outcome of the result?

Case Study : A galvanising business in a heavy industrial area

(extracted from: Land use planning guide for hazardous facilities: a resource for local authorities and hazardous facility operators. MfE, 2002)

This example applies the HFSP to a proposed galvanising business in a heavy industrial area, close to a stream, to find out if the application requires a land use consent for the use of hazardous substances. The activity will include the use of baths of hydrochloric acid and molten zinc.

Step 1: Describe hazardous substances likely to determine consent status

List the substances proposed to be used or stored on the site which are likely to determine the consent status.

Comment:

The HFSP has been calibrated on the weight of the pure substance (except for compressed gases, which are measured in cubic metres). Therefore, volumes need to be converted to weights, using the specific gravity, or density, of the substance. For mixtures, the weight of the pure substance is derived from its relative percentage in the mixture. However, it should be remembered that there are some cases where the substance rating already accounts for the dilution, notably for substances with corrosive properties, oxidising capacity and some toxic substances, in particular those used as pesticides. In this case study, ammonium hydroxide containing more than 10% but less than 35% of ammonia in solution has a specific gravity of 0.89. Hydrogen peroxide is also classified according to concentration, while a 33% hydrochloric acid solution is generally regarded as commercial strength, and this concentration would rarely be exceeded. Consequently, no dilution factor needs to be applied, and the conversion of litres to tonnes yields the following weights:

The substance list can be presented in a simple format, as follows:

Step 2: Identify Hazard Rating

Use the information recorded in Appendix B or the rating criteria in Appendix A to find the Effect Types and corresponding hazard ratings for the substances being assessed, and note them in a table as shown below:

Comment:

The rating of substances for the purposes of the HFSP is done according to the criteria in Appendix A of the Red Book . For some commonly used substances the rating has already been established, and these are provided in Appendix B of the Red Book.

It is noted that, in terms of the application of the HFSP, the assessment of hydrochloric acid alone would have indicated the need for a land use consent. In this instance the HFSP would not need to be applied to other substances.

Step 3: Find Base Quantities

Use Table 3 in the main document to find the Base Quantities for each substance and record in a table, as below:

Step 4: Calculate Adjusted Quantity by multiplying Base Quantities with Adjustment Factors

Refer to Table 4 in the main document to find the Adjustment Factors. This needs to be done in two steps:

1. listing the values for individual Adjustment Factors for the applicable Effect Types; and
2. multiplying the individual factors to obtain one overall Adjustment Factor for each Effect Type.

Comment:

The choice of Adjustment Factors depends on substance and site-specific aspects. In this case, no separation distance to the site boundary is greater than 30 metres. This influences the choice of Adjustment Factor FF3 for the Fire/Explosion Effect Type. Although the Human Health Effect Type also includes an Adjustment Factor for separation distance, this is only applicable to gases to account for the effects of toxic gases on human health. Also of interest is the proximity of a stream, which influences the choice of Adjustment Factor FE2 for the Environmental Effect Type. Finally, all substances are stored above ground with the exception of the hydrochloric acid and the molten zinc (zinc ammonium chloride), which is constantly in use.

Record the Adjusted Quantities in a table such as the one below:

Step 5: Calculate Quantity Ratios

Calculation of Quantity Ratios requires dividing the Proposed Quantity of a substance by the Adjusted Threshold for each Effect Type. Record the results in a table, as shown below:

Step 6: Determine the proposal’s consent status

Select the highest Total Quantity Ratio of the three Effect Types and compare it with the ratios in the Consent Status Matrix to see whether the facility requires a resource consent. If the Quantity Ratio for one or more of the Effect Type exceeds the index for the zone where the facility is proposed, a resource consent will be required.

Discussion

Largely as a result of the large quantity of hydrochloric acid used on the site, the Quantity Ratios for the Human Health Effect Type is greater than the consent status index generally set for industrial areas. The proposed development would therefore require a resource consent.

A sample sheet showing the above calculations as carried out with the HFSP Spreadsheet Calculation Package is provided below.

Key application

Identify a key application of the information you’ve learnt in your day-to-day working environment.

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