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QAF011 Rev. 03 Feb. 26, 05

Process Safety Management (PSM)

November 12-16, 2005 NPC of Iran

Mahshahr, Iran

Course Instructor(s) Mr. Keith Balchin

Haward Technology Middle East

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To The Participant

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Disclaimer

The information contained in these course notes has been complied from various sources and is believed to be reliable and to represent the best current knowledge and opinion relative to the subject. Haward Technology offers no warranty, guarantee, or representation as to it’s absolute correctness or sufficiency. Haward Technology has no responsibility in connection therewith; nor should it be assumed that all acceptable safety and regulatory measures are contained herein, or that other or additional information may be required under particular or exceptional circumstances.

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Table of Contents

Section 1 Introduction Section 2 Hazard Analysis & Operability Study

(HAZOP) Section 3 Hazard Identification Section 4 Hazard Communication Section 5 Hazard Recognition Section 6 Personal Protective Equipment (PPE) Section 7 Safety Inspection & Audits Section 8 Planning & Organization Section 9 Emergency Response Plans Section 10 Safe Operations Section 11 Hazardous Chemicals Section 12 Monitoring Equipment Section 13 Appendices: Case Studies, Examples & Forms

Section 1

Introduction

1

Process Safety Management (PSM)

Presented byKeith Balchin Pr Eng

2

Introduction

Section 1

3

Introduction

• Course Objectives:– Upon the successful completion of this course,

participants will gain good skills and knowledge on the following areas:

• Process Safety Management (PSM)• Employee Involvement • Process Hazard Analysis • Operating Procedures • Training of the Employees• Controlling Contractors • Pre-startup Safety Review

4

Introduction

• Course Objectives Continued:• Mechanical Integrity • Hot Work • Management of Change • Incident Investigation• Emergency Planning & Response • Internal Compliance Audits/Inspections

5

Introduction

• The Eight Principles of a Safe Workplace:1. Safety is an Ethical Responsibility 2. Safety is a Culture Not a Program 3. Management is Responsible 4. Employees Must Be Trained to Work Safely 5. Safety is a Condition of Employment 6. All Injuries Are Preventable 7. Safety Programs Must Be Site Specific with

Recurring Audits of the Workplace and Prompt Corrective Action

8. Safety is Good Business

6

Introduction• Definitions;

Explosion:An explosion can be defined as a "rapid oxidation in a confined space". An "oxidation" of this type is an "oxidation reduction reaction with the evolution of heat and light" which is the definition of fire. In other words, an explosion is a confined fireUEL :The UEL (Upper Explosive Limit) is the concentration above which the mixture is too "rich" to burn (too much fuel or too little air)

LEL :The LEL (Lower Explosive Limit) is the concentration below which the mixture is too "lean" to burn (not enough fuel or too much air).

Flash Point:Flash Point is the lowest temperature at which a material gives off enough vapours to form an ignitable mixture with air

7

Introduction

• Definitions ContinuedHazardous Liquids :Flammable liquids are usually defined as liquids having a flashpoint less than or equal to 61oC. It is important to note that liquids do not burn. Only the vapors they produce may burn. Therefore a flammable liquid that is not readily producing vapors (like kerosene) is much safer than a flammable liquid that is constantly producing vapors (like gasoline).Toxic liquids are those that are toxic by skin absorption, ingestion, or injection. Only their vapours could be toxic by inhalation. Therefore if the liquid is not readily producing vapours it is more safe than if it were producing vapors

8

Introduction

• Definitions ContinuedCorrosives :Corrosives include acids and caustics. Caustics are also referred to as bases or alkalis.–pH is a method of expressing the intensity of an acid or base that is determined by measuring the hydrogen-ion concentration. –pH is measured on a logarithmic scale which ranges from 1 to 14.–A pH < 7 indicates an Acid, while a pH > 7 indicates a base (alkali or caustic). A pH of 7 is neutral.–The lower the pH the more acidic a material is. –The higher the pH the more caustic a material is.–Both acids and caustics are corrosive since they will both damage skin and deteriorate metal

9

Introduction

• Definitions ContinuedOxidizers :Oxidizers are chemicals that can take the place of oxygen in a fire. For example many materials will burn in a chlorine atmosphere with no oxygen present.Flammable Solids :Flammable Solids are solids that readily ignite and burn vigorouslyMelting Point :Melting Point is the temperature at which a solid changes to liquid. Inorganic materials usually have higher melting points than organic materials.Reactivity :Reactivity is the tendency of a material to react with other substances

10

Introduction

• Definitions ContinuedToxicology:Toxicology is the study of chemical or physical agents that produce adverse health effects

PEL:PEL stands for Permissible Exposure Limits. This is an OSHA termand represents the maximum allowable exposure for a specific time period

STEL:STEL stands for Short Term Exposure Limit which is based on a specific time period, often 15 minute exposure, for a maximum of 4 times/day, with a minimum of 1 hour between exposures, provided the TLV and TWA are not exceeded.

11

Introduction

• Definitions ContinuedTLV:TLV stands for Threshold Limit Value, which is the airborne concentration of a material that nearly all persons can be exposed day after day without adverse effects

8-hour Time Weighted Average (TWA) :8-hour Time Weighted Averages (TWA) are an average value of exposure over the course of an 8 hour work shift.

CAS No:A CAS (Chemical Abstracts Service) Registry Number is a unique identifier that tells you, for example, that acetone and dimethylketone are actually the same substance . The Chemical Abstracts Service, http://www.cas.org/, is a division of the American Chemical Society, http://www.acs.org/.

12

Section 2

Hazard Analysis & Operability Study (HAZOP)

13

Hazard Analysis and Operability Study (HAZOP)

Section 2

14

Other Tools – HAZOP Studies

• Definition of a HAZOP Study:– A Hazard and Operability Study (HAZOP) is a

structured risk study process for identifying hazards and design deficiencies which prevent safe and efficient operation of plant and machinery

• Purpose of a HAZOP Study:– The purpose of a HAZOP is to identify and address

hazards and design deficiencies in order to ensure safe, hazard free, and operable operations.

– Rigorous implementation will ensure compliance with accepted SHE (Safety, Health and Environment) standards and legislated requirements

15


• APPLICABILITY:– A HAZOP is applicable to new plant, processes or

equipment, or modifications to existing plant, processes or equipment

– A HAZOP is a method for early identification of potential safety issues, for example:• Spillages• PPE requirements• Lock-out requirements• Procedures• Training

16


• HAZOP Study Process:1. Identify and record all the attendees for each HAZOP

study2. Define the system3. Select a line/component (e.g. boiler feed line, etc.).4. Work through the HAZOP Checklist and record all

information – deviations/potential hazards are marked “yes” and given a reference number

5. For each deviation reference number complete the causes, potential consequences, existing safeguards and further requirements on the HAZOP GAP List

6. Repeat the process for each line/component7. Sign off once complete.

17


• HAZOP Guide Words:

– The words in the following tables are used to prompt possible deviations to be investigated

– Parameters and/or guidewords can be added as required to define a risk factor/deviation.

18

Other Tools – HAZOP StudiesHAZOP GUIDE WORDS AND DEVIATIONS

More of any physical property than there should be, e.g. higher flow (rate or total quantity), higher temperature, higher pressure, higher viscosity, higher concentrations etc.

More of/Too much

Less of any physical property than there should be, e.g. less flow (rate or total quantity), less temperature, less pressure, less viscosity, inadequate lubrication, ventilation, cooling, guarding, etc.

Less of/Inadequate

No flow when there should be or reverse flow instead of forward flow, e.g. product, electricity, compressed air, etc.

None/Loss of

Deviations GeneratedGuide Words

19

Other Tools – HAZOP StudiesHAZOP GUIDE WORDS AND DEVIATIONS (Cont.)

What else can happen apart from normal operation, e.g. shutdown, up rating, low rate running, alternative operation mode, failure of plant services, maintenance, etc.

Other than

More components present in the system than there should be e.g. impurities (air, water, acids, corrosion products), explosive or combustible substances etc.

More than

Occupational and environmental exposures that deviate from standards and legislation, e.g., noise, emissions, pollutants, etc.

Unacceptable

Composition of system different from what it should be, e.g. change of ratio of components, component missing, etc

Part of

Deviations GeneratedGuide Words

20


Low Level

High Level

Freezing

Low temperature

High Temperature

Reverse Flow

No Flow

Low Flow

High Flow

Vacuum

Low pressure

High Pressure

Inaccessibility

Training and Licensing

Procedures/Work Instructions

Material Safety Data Sheets

Drawings

Ref. NoYesNo

Potential Problem?Process Parameter (Max/Min)/Description

Potential Deviation/Hazard

21


Civils

Fire Protection

Cathodic Protection

Critical Pipes

Dead Legs

Sewers/Drains

Vents/Drains/Sample Points

Vibration

Corrosion/Erosion/Wear

Line Compatibility

Temperature Relief

Pressure Relief

Other Material/Product

Contamination

Phase change

Property (pH, density, viscosity)

Ref. NoYesNo



22


Tie-in Requirements

Maintainability

Legal Requirements

Operability

Ergonomics

Toxic Substances

Pollution/Emissions

Ventilation

Lighting Ventilation

Colour Coding/Labelling

Lock outs/Isolation

Noise

Registration/Approvals

Protective Clothing

Guarding

Electrical Classification

Electrical/Control System

Utilities (electricity, water etc.)

Ref. NoYesNo



23


Signature:

Name:

Authorized By:

K10

K9

K8

K7

K6

K5

K4

K3

K2

K1

Completed(Date)

By When

By Whom

Description of Action Item

ExistingSafeguards

Potential Consequences

CausesPotentialDeviation/Hazard

Ref. No

1of1Page26 September 2005Date:Project:

HAZOP GAP LIST

24

Section 3

Hazard Identification

25

Hazard Identification

Section 3

26

Toxicology Concepts

"All substances are poisons; there is none which is not a poison. The right dose differentiates a poison…." Paracelsus (1493-1541)

27

Toxicology Concepts

• Toxicology is the science that deal with the adverse effects of chemicals on living systems.

• A substance can produce the harmful effect associated with its toxic properties only if it reaches a susceptible biological system within your body in a sufficient concentration (a high enough dose).

• The toxic effect of a substance increases as the exposure (or dose) to the susceptible biological system increases.

28

Toxicology Concepts

• Speciality Areas in Toxicology:– Target Organ/System.

• Neurotoxicology, Genetic Toxicology, Reproductive Toxicology, Immunotoxicology etc

– Target Species/Systems.• Human Toxicology, Aquatic Toxicology, Environmental

Toxicology, Wildlife Toxicology, Veterinary Toxicology.

– Selected Responses.• Teratology,

Carcinogenesis etc.

29

Toxicology Concepts

• Applied Toxicology:– Occupational toxicology.– Clinical toxicology.

• Toxic induced diseases and antidotes.– Forensic toxicology.

• Determining causes of death.– Regulatory toxicology.

• Legislation, Standards & Risk assessment.– Developmental toxicology.

• New chemicals and uses.

30

Toxicology Concepts

• Classification of Toxicants:– Target organ.

• Hepatotoxin, neurotoxin etc.

– Intended use.• Pesticide, solvent etc.

– Source.• Natural, synthetic.

– Special effect.• Carcinogen, mutagen, endocrine disruptor etc.

31

Toxicology Concepts

• Classification of Toxicants Continued:– Physical state.

• Gas, solid.

– Toxicity.• Extremely, slightly.

– Chemical composition.• Heavy metal, etc.

– Mechanism of action.• Anticholinergic, inhibitor,

uncoupler.

32

Toxicology Concepts

• Types of Toxic Responses:– Local:

• Effect at site of contact.• GIT, lungs.

– Systemic:• Effect distant from exposure site.• CNS, kidney, lungs.

– Immediate:• Minutes to hours after a single exposure.

– Delayed:• Days to years after exposure.

33

Toxicology Concepts

• Types of Toxic Responses Continued:– Reversible vs. Irreversible– Largely determined by

• Tissue involved, length of exposure and magnitude of toxic insult.

– Reversible - rapidly regenerating tissue.• Liver, intestinal mucosa, blood cells.

– Irreversible• Carcinogenesis,

mutagenesis, etc.

34

Toxicology Concepts

A material that deprives tissue of oxygen and causes suffocation by displacing oxygen or interfering chemically with oxygen absorption, transport or utilization

Asphyxiant:

A material that can destroy human tissue. Includes both acids and bases and may be a solid liquid or gas. Most common toxic material encountered in the laboratory.

Corrosive:

Causes inflammation of the skin and mucous membranes (skin, eyes, nose, or respiratory system).

Irritant: Physiological Classification of Toxic Responses

35

Toxicology Concepts

Causes kidney damage. Example: chloroform, mercury, dimethyl sulfate

Nephrotoxin:

Affects the nervous system. Example:mercury, lead, carbon disulfide

Neurotoxin:

Causes liver damage. Example: carbon tetrachloride

Hepatotoxin:

Depresses the central nervous system Example: alcohols, halogenated hydrocarbons

Anesthetic: Physiological Classification of Toxic Responses

36

Toxicology Concepts

Causes impotence or sterility in men and women. Example: lead, dibromodichloropropane

Reproductive toxins:

A material which can cause cancer. Example: asbestos, Bis-chloromethylether, benzene, acrylonitrile

Carcinogen:

Irritates or damages the lungs. Example: asbestos, silica ozone. chromium

Pulmonary toxin:

Affects the cellular components of blood or its ability to function Example: benzene, xylene, CO, cyanides

Hematopoietictoxin:

Physiological Classification of Toxic Responses

37

Toxicology Concepts

A material which interferes with the developing embryo when a pregnant female is exposed to that substance. Example: lead, thalidomide

Teratogen:

Anything which causes a change in the genetic material of a living cell. Many mutagens are also carcinogens.

Mutagen: Physiological Classification of Toxic Responses

38

Toxicity Rating – Oral Human Dose

A taste (<7 drops)<5 mg/kgSuper toxic

Between 7 drops and a teaspoonful

5-50 mg/kgExtremely toxic

Between a teaspoonful and an ounce

50-500 mg/kgVery toxic

Between an ounce and a pint

0.5-5 g/kgModerately toxic

Between a pint and a quart

5-15 g/kgSlightly toxic

More than a quart>15 g/kgPractically non-toxic

For Average AdultDoseClass

Cassarett and Doull

39

Toxicology Concepts

• Measures of Toxic Effect:– Acute toxic effects (those that occur after a single

exposure) of substances are typically measured in animals (rats and mice) and defined in terms of the lethal dose 50 (LD50) or lethal concentration 50 (LC50).

– The LD50 is defined as the amount of chemical that when ingested, injected, or applied to the skin of a test animal, will be lethal to fifty percent of the test population

– The LD50 is typically expressed in milligrams of test substance per kilogram of body weight.

40

Spectrum of Toxic Dose

0.00001Botulinus toxin0.001Dioxin (TCDD)0.1Tetrodotoxin0.5d-Tubocurarine1Nicotine2Strychnine sulfate5Picrotoxin

100DDT150Phenobarbitol900Morphine sulfate

1,500Ferrous sulfate4,000NaCl10,000Ethanol

LD50 (mg/kg)Agent

Cassarett and Doull

41

Toxicology Concepts

• Acute and Chronic Health Effects:– Acute health effects are characterized by sudden

and severe exposure and rapid absorption of the substance. Normally, a single large exposure is involved. Acute health effects are often reversible. Examples: carbon monoxide or cyanide poisoning.

– Chronic health effects are characterized by prolonged or repeated exposures over many days, months or years. Symptoms may not be immediately apparent. Chronic health effects are often irreversible. Examples: lead or mercury poisoning, cancer.

42

Toxicology Concepts

• Local vs Systemic Health Effects:– A Local effect refers to an adverse health effect that

takes place at the point or area of contact. The site may be skin, mucous membranes, the respiratory tract, gastrointestinal system, eyes, etc. Absorption does not necessarily occur. Examples: strong acids or alkalis.

– A Systemic effect refers to an adverse health effect that takes place at a location distant from the body's initial point of contact and presupposes absorption has taken place. Examples: arsenic effects to the blood, nervous system, liver, kidneys and skin; benzene effects to the bone marrow.

43

Risk Assessment

• What is Risk?– A risk is an uncertainty to which a probability can be

assigned on a scale of 0 to 1:• The probability of dying is 1 and of living forever is 0• Sometimes probability is measured on a scale of 0 to 100%• The assessment or measurement of risk is subjective

• Risk Analysis:– Develops an understanding and awareness of risk

associated with a particular variable or system

• Risk Management:– Is the process of systematically identifying, assessing

and preparing for risk.

44

Risk Assessment

• Risk in Processes:– This is any event that could arise, and would cause

failure of an item or items.– Three risk factors must be identified in order to

consider risk:1. The risk event itself – its nature and its consequences2. The probability that the risk event will occur3. The financial loss and other consequences which will result

such as:– Loss of Production – Accidents/Safety Effects– Pollution/Environmental Effects– etc.

45

Risk Assessment

• Risk Quantification:– The criticality or importance of each failuremode can be

determined by assigning a probability– The probability can be:

• An estimate, or• It can be derived from any combination of:

– Failure rates– Design error probability– Operator error probability– Failure of alarm systems, or – Failure of preventative maintenance.

– The severity of each potential failure mode is assigned on a predetermined scale, which may be numerical or qualitative, for example minor, significant, major and catastrophic.

46

Risk Assessment

• Dealing with Risk:– Having identified, quantified and prioritized the risk one

must respond and deal with the risks. One can:• Eliminate the risk and avoid it completely:

– Remove the cause, Change the design, etc.• Mitigate (reduce) the risk:

– Develop safe work instructions, training, use PPE, implement preventative maintenance etc.

• Transfer or deflect the risk :– Use expert contractors etc.

• Accept risk and prepare for it by:– Preparing emergency plans etc.

47

Risk Assessment

Severity CatastrophicMinor

RISK MATRIX DIAGRAM

Probability or

Relative

Frequency0

20

40

60

80

100

48

Section 4

Hazard Communication

49


““EmployeeEmployee’’s Right to Knows Right to Know””

Section 4

50


• Chemical exposure may cause or contribute to many serious health effects such as heart ailments, kidney and lung damage, sterility, cancer, burns, and rashes.

• Some chemicals may also be safety hazards and have the potential to cause fires and explosions and other serious accidents.

• Because of the seriousness of these safety and health problems, and because many employers and employees know little or nothing about them, it is important to have formal Hazard Communication.

• The US Occupational Safety and Health Administration (OSHA) has issued a standard called "Hazard Communication."

51


• Written Hazard Communication Plan:– Employers must develop, implement, and maintain at

the workplace a written, comprehensive hazard communication program that includes provisions for:

• Container labeling, • Collection and availability of material safety data sheets, and an• Employee training program.

– The Plan must contain a list of the hazardous chemicals in each work area, the means the employer will use to inform employees of the hazards of non-routine tasks (for example, the cleaning of reactor vessels), and the hazards associated with chemicals in unlabeled pipes.

52


• Responsibility for Hazard Information:– Manufacturers/Importers:

• determine hazards• responsible for quality of hazard determination

– Manufacturers/Importers and Distributors: • communicate hazard information to customer

– Employers• When employers make any changes to an Material Safety Data

Sheet (MSDS) they become responsible

• Manufacturers/Importers Convey Information by :– Labels on Containers – MSDS

53


• Employer Responsibilities :

– Identify, List Hazardous Chemicals in Workplace– Obtain MSDS's & Labels– Written HAZCOM Program– Provide Info. to Employees– Hazard Evaluation– Accept MSDS– Ensure that Employees must have the knowledge of chemistry &

toxicology necessary to understand all forms of emergency information available to him/her

54


• Training Chemistry/Toxicology :– Employees must have the knowledge necessary to

understand all sources of hazard information available to them.

• Emergency Information:– Material Safety Data Sheets– Manufacturer's Product Labels– Warning Labels– Shipping Papers

55


• Written HAZCOM Programme :– Provisions for Labeling– MSDS’s– Training Programme– Training Records– List of Hazardous Chemicals in Work Area– Means to inform employees:

• Hazards of Non-RoutineTasks• Hazards Associated with Chemicals in Unlabeled Pipes

– Must be available to:• Employees• Employee’s Designated Representatives• OSHA Inspectors

56


• Labels and Warnings:

HEALTH4

FIRE0

REACTIVITY2

PPE

HEALTH4

FIRE0

REACTIVITY2

PPE

57


• Retain Transport (DOT) Labels:– Unless replaced– Until empty– Until triple rinsed

• DOT Labeling System:– Colour Coded – Graphic Symbols– Hazard– Hazard Class & Division # 8

58


• HAZMAT (DOT) Marking:– Proper (DOT) Shipping Name– (DOT) ID Number

• Exemptions/Exceptions to Employer Labeling :– Not Required to Label Portable Containers if:

• Contents Transferred from Labeled Containers• Intended for Immediate Use of Transferring Employee

– Pesticides– Any material defined as a Food, Drug or Cosmetic

59


• Material Safety Data Sheets (MSDS) must include:– Specific Chemical Identity – Common Names– Characteristics– Acute and Chronic Effects– Exposure Limits– Whether a Carcinogen– Precautionary Measures– Emergency & First Aid– Preparer of MSDS

60


• MSDS’s not required for:– Household Quantity– Household Use

• MSDS Facts:– They are Not a Final Source of Information– They do Not Contain Incomplete Information– There is No Standard Format

• Copies of MSDS's Must be Readily Accessible to Employees

61


• List of Hazardous Chemicals:– Employers must prepare a list of all hazardous

chemicals in the workplace.– When the list is complete, it should be checked against

the collected MSDS's that the employer has been sent.– If there are hazardous chemicals used for which no

MSDS has been received, the employer must write to the supplier, manufacturer or importer to obtain the missing MSDS.

62


• The employee training plan must consist of the following elements:– How the hazard communication program is implemented

in the workplace, how to read and interpret information on labels and the MSDS, and how employees can obtain and use the available hazard information

– The hazards of the chemicals in the work area. (The hazards may be discussed by individual chemical or by hazard categories such as flammability.)

– Measures employees can take to protect themselves from the hazards.

63


– Specific procedures put into effect by the employer to provide protection such as engineering controls, work practices, and the use of personal protective equipment (PPE).

– Methods and observations, such as visual appearance or smell, that workers can use to detect the presence of a hazardous chemical to which they may be exposed.

64

Section 5

Hazard Recognition

65

Hazard Recognition

Section 5

66

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Statutory and regulatory requirements regarding

flammability arevery important and users, distributors, and transporters so they can better understand these requirements.

– Some hydrocarbon and oxygenated solvents readily evaporate and are highly flammable.

– These solvents need to be managed carefully to minimize risks of a fire or explosion, particularly during loading and unloading, storing, and when using in bulk.

– Safe handling information provided by the supplier should be carefully followed

67

Hazard Recognition

• Handling Flammable Liquids and Vapours:– When solvent vapors are mixed with air they may (like

gasoline vapors) form flammable mixtures that will ignite and burn when exposed to a spark or flame.

– Solvents can be handled safely if common sense precautions are understood and followed. These precautions are based on the following principles:

• Vapours burn when mixed with air (or other sources of oxygen) in certain proportions.

• Air vapor mixtures burn when a source of ignition is ignited. • Liquid or vapor can settle in low areas and travel along the

surface

68

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Fire hazard or explosion can be minimized by:

• Controlling vaporization • Controlling air-vapour concentrations • Eliminating ignition sources (sparks, flames, static electricity

and excessive temperatures) • Eliminating spills

69

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Flammable limits and flash point:

• In a solvent/air mixture, the proportion of solvent vapor that makes it flammable is of primary importance.

• The flammable limits typically range for most products from about 1% to 10% at atmospheric pressure.

• Typically if there is less than 1% of solvent vapor or more than 10% (depending upon the solvent), the mixture is either too lean or too rich to burn.

• For a particular solvent, the lowest temperature at which vaporis produced in sufficient concentrations to create a flammable mixture (approximately 1%) under test conditions is its flash point

70

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Flammable limits and flash point continued:

• Flash point is a major factor in establishing safety procedures.• Closed cup flash point is usually used in defining the degree of

hazard. • The Closed Cup Flash Point is the temperature at which the

equilibrium of a vapour over a flammable liquid is equal to the flammability limit of the vapour.

• As an example the closed cup lower explosion limit (LEL) of toluene is 4.44 oC

• OSHA defines materials with flash points of less than 100° F (37.8oC) as "Flammable."

71

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Preventive measures:

• Anyone using or handling solvents or any other flammable materials should be aware of the hazard of spark-ignited fire and explosion, and all appropriate measures should be taken to eliminate ignition sources, prevent static electric charge build-up, and accumulation of flammable vapours in air.

• General preventive measures may include the following: – To prevent static-buildup, for example, bond or ground

equipment to provide a conductive electrical path. – Keeping solvent containers closed in the workplace. – Establish procedures to minimize splashing and spraying of

solvents being transferred; for example, transferring liquid into a tank.

– Eliminate ignition sources in the workplace.

72

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Preventive measures continued:

• Handling and preventive measures may be specific to each product. See the MSDS and the manufacturer's directions for specific handling directions for each product.

• Use an approved Safety Can shall mean an approved container, having a spring-closing lid, flame arrestor and spout cover which is so designed that it will safely relieve internal pressure when subjectedto fire exposure.

73

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Autogenous Ignition :

• Ignition may also occur without a spark or flame. • If the product is heated well above its flash point, a

temperature is reached at which the product will ignite spontaneously, without any external source of ignition, provided sufficient oxygen is present.

• This is called autogenous ignition and the temperature at which it occurs is the auto-ignition temperature of the product.

• Users should never exceed the auto ignition temperature of any solvent.

74

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Sources of ignition energy can be classified into 4

categories:• Flames and Smoldering• Hot Surfaces• Friction and Impact• Electrical Discharges (Electrical Power and Static Electricity)

– Flames and Smoldering:• This category of ignition sources includes all open flames such

as welding torches, matches, and gas burners, as well as sporadic sources such as the exhaust of an engine.

• Smoldering covers all forms of incandescent materials such as cigarettes

75

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Hot Surfaces:

• Hot surfaces may cause ignition of flammable solvent/air mixtures either directly or indirectly.

• Direct ignition will occur if the surface is at a temperature above the autoignition temperature of the solvent/air mixture in the particular system considered.

• Indirect ignition results from the burning or smoldering of material initiated by a hot surface.

• Hot surfaces are widespread in industrial areas; examples include walls of ovens and furnaces, electrical equipment etc.

• Some operations can easily produce hot spots; examples are grinding, cutting, and welding operations.

76

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Friction and Impact:

• Localised hot spots and incandescent sparks mainly arise from friction, and depend largely on the materials. For example, sparks produced during impacts involving metals (magnesium and their alloys, iron) with certain objects.

– Electrical Discharges:• Electrical discharges can be very widespread and may be

hidden. They generally arise from two basic sources: electrical power and electrostatic discharges.

77

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Electrical Power:

• Main grid electricity as well as batteries are potential sourcesof sparks which can have sufficient energy to ignite solvent vapor/air blends

• Routine operation of transformers, motors, circuit breakers etc.can be electrical ignition sources

• Electrical failures such as damaged cables, bad connections etc. can also be electrical ignition sources.

• Electromagnetic waves emitted by radio antennae may give rise to sparks in their vicinity.

78

Hazard Recognition

• Handling Flammable Liquids and Vapours:– Electrostatic Discharges/Static Electricity:

• One of the least understood and most difficult ignition sources to control is static electricity.

• Static electricity is produced by pumping of materials or by anyother means of motion, such as agitation. The motion separates positive and negative charges, which then accumulate in the liquid and the containment system -example, lines, tanks, drums etc.

• The charge on the containment system is dissipated quickly by earting/grounding, but the charge in the liquid remains and is slowly dissipated, depending on the conductivity of the liquid.

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Hazard Recognition

• Handling Flammable Liquids and Vapours:– Some examples of processes that can produce static

electricity:• High velocity and conditions in the discharge of jets from

nozzles.• The movement of vehicles, fans or even people.• Movement or transport of powders and dust.• Liquid droplets falling through a vapour.• High velocity release of steam to the atmosphere.• Mechanical movements such as belts, pulleys etc.• etc.

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Hazard Recognition

• Handling Flammable Liquids and Vapours:– Minimum Igntion Energy (MIE):

• Irrespective of the potential source of ignition, it must deliver a certain minimum amount of energy to initiate a flame front in the fuel/air mixture.

• Very low energy levels can be sufficient to ignite solvent vapour/air mixtures (~0.01 – 2.0 milli joules).

• Likewise very low energy levels can be sufficient to ignite certain gases – for example the MIE for hydrogen is 0.017 mJ.

• A spark from a metal tool falling on the floor or struck against a metal drum, or a spark from an electrical switch or motor commutator may have sufficient energy to ignite a fire if the solvent vapours in air are within the flammable range

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Hazard Recognition

• Handling Flammable Liquids and Vapours:– A summary of the Key Safety Considerations for

Handling Flammable Liquids and Vapours:• Follow Appropriate Regulations and/or Standards Applicable

to Handling and Storage of Flammable Liquid/Vapour.• Understanding the specific physical and chemical properties of

the Flammable Liquid/Vapour. The supplier’s Material Safety Data Sheet (MSDS) should be consulted for basic information and the National Fire Protection Association (NFPA), manufacturers or suppliers should be consulted for additional information.

• Identifying potential ignition sources and address them• Many vapours and gases are heavier than air and steps

should be taken to guard against the migration of the vapor to an ignition source.

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Hazard Recognition

• Handling Flammable Liquids and Vapours:– A summary of the Key Safety Considerations for

Handling Flammable Liquids and Vapours continued:• Understand Conditions for Autoignition.• Control Static Electricity.• Maximize Ventilation as Appropriate to the Application so as to

dilute the Flammable Liquid/Vapour.• Maintain the Appropriate Work Temperature. Lower ambient

temperatures can slow the volatilization of solvents, thereby decreasing the rate at which solvent vapors enter the atmosphere.

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Hazard Recognition• Handling Flammable Liquids and Vapours:

– A summary of the Key Safety Considerations for Handling Flammable Liquids and Vapours continued:

• Appropriate education, information, instructions, and training must be provided to employees.

• Report Leaks and Spills.• Providing Secondary Containment Solutions where appropriate.• Develop Correctt Loading and Unloading Procedures.• Where appropriate, consider use of inert storage practices such as

nitrogen blankets to help remove oxygen from the system.• Develop Standard Operating Procedures (SOP’s) e.g for handling

solvents, minimizing leaks, and dissipating static charge.• Develop an Emergency Plan.

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Hazard Recognition

• Handling Corrosive Materials:– What are corrosives?

• They are materials that can attack and chemically destroy exposed body tissues. Corrosives can also damage or even destroy metal.

• They begin to cause damage as soon as they touch the skin, eyes, respiratory tract, digestive tract, or the metal. They might be hazardous in other ways too, depending on the particular corrosive material.

• Most corrosives are either acids or bases. • Common acids include hydrochloric acid, sulfuric acid, nitric

acid, chromic acid, acetic acid and hydrofluoric acid • Common bases are ammonium hydroxide, potassium

hydroxide (caustic potash) and sodium hydroxide (caustic soda).

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Hazard Recognition

• Handling Corrosive Materials:– How are corrosives hazardous to health?

• Corrosives can burn and destroy body tissues on contact. The stronger/more concentrated the corrosive material is and the longer it touches the body, the more severe the injuries will be.

• Some corrosives are toxic and can cause other health problems. The MSDS and label on the container should be checked for warnings of other possible adverse health effects.

• Corrosive materials can severely irritate or burn the eyes which could result in scars or permanent blindness. The stronger/more concentrated the corrosive material is and the longer it touches the eyes, the worse the injury will be.

• Corrosives touching the skin can severely irritate or even badly burn and blister the skin. Severe corrosive burns over a large part of the body can cause death.

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Hazard Recognition

• Handling Corrosive Materials:– How are corrosives hazardous to health?

• Breathing in corrosive vapours or particles irritates and burns the inner lining of the nose, throat, windpipe and lungs. In serious cases this results in pulmonary edema, which is a buildup of fluid in the lungs that can be fatal.

• Swallowing corrosives burns the sensitive lining of the mouth, throat, esophagus and stomach. In nonfatal cases, severe scarring of the throat may occur and could result in losing the ability to swallow.

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Hazard Recognition• Handling Corrosive Materials:

– The hazards when corrosives touch metals:• Many corrosives attack and corrode metals. • Contact with corrosives can damage containers, equipment,

installations and building components made from unsuitable materials.

• The rate of metal corrosion is greater when the corrosive is stronger and the temperature is higher.

• When acids attack metals, hydrogen gas is often given off. This is a flammable gas which can burn or explode if an ignition source ispresent.

• Common bases, such as sodium hydroxide and potassium hydroxide, can also attack some metals like aluminum, zinc, galvanized metal and tin to produce hydrogen gas.

• The MSDS for a particular corrosive should explain which metals or other materials it will attack.

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Hazard Recognition

• Handling Corrosive Materials:– Working Safely with Corrosive Liquids and Solids :

• Substitution can be the best way to avoid or reduce a hazard. Whenever possible Choose the least hazardous materials that can do the job effectively and safely.

• Correctly designed and maintained ventilation and extraction systems remove corrosive vapours, fumes, mists or airborne dusts from the workplace and reduce their hazards.

• Before storing corrosives all incoming containers of corrosives should be inspected to ensure that they are undamaged and properly labelled. Deliveries of defective containers should notbe accpeted.

• Corrosives can destroy containers made of incorrect materials. Be sure to store corrosive materials in the type of containers recommended by the manufacturer or supplier.

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Hazard Recognition

• Handling Corrosive Materials:– Working Safely with Corrosive Liquids and Solids

continued:• Keep containers of corrosives tightly closed when not in use.• In general corrosives should be stored separately, away from

processing and handling areas, and from other materials. • Separate storage can reduce the amount of damage caused in

the case of fires, spills or leaks. • When totally separate storage of corrosives is not possible

they should be stored away from incompatible materials. • Some corrosives are incompatible with each other. For

example, acids and bases react together, sometimes violently. Do not store them together.

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Hazard Recognition

• Handling Corrosive Materials:– Working Safely with Corrosive Liquids and Solids

continued:• Walls, floors and shelving in corrosive storage areas should be

made from materials that resist attack by the corrosives being stored.

• Floors in areas where liquid corrosives are stored should not permit penetration of the liquids

• Because many corrosive liquids flow easily the containers should be stored in corrosion resistant trays to contain spills or leaks. For large containers bunds should be built around liquid storage areas and sills or ramps installed at door openings.

• Containers should be installed at a convenient height for handling, below eye level if possible. High shelving increases the risk of dropping containers and the severity of damage if a fall occurs.

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Hazard Recognition

• Handling Corrosive Materials:– Corrosives should be stored in areas which are:

• Well ventilated. • Supplied with adequate fire fighting equipment. • Labelled with proper warning signs. • Supplied with suitable spill clean-up equipment and materials.

– General rules for storing corrosive materials: • Only trained, authorized people should be allowed into storage

areas. • The amount of corrosive material in storage should be as

small as possible. • Inspect storage areas regularly for any deficiencies, including

corrosion damage, leaking containers, or poor housekeeping. Correct all deficiencies as soon as possible.

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Hazard Recognition

• Handling Corrosive Materials:– Handle corrosive containers safely:

• Always handle containers of corrosives carefully - damaged containers may leak.

• Many workplaces receive corrosive liquids in large metal drums or barrels and fill smaller containers from them. Moving full drums by hand can be difficult and hazardous. Drums can be moved in specially designed drum cradles which can also be used as individual drum storage racks.

• Use special caddies for bulky bottles of corrosives and safety bottle carriers for smaller sized bottles of corrosives.

• Self-closing, portable containers for carrying, storing, and dispensing small amounts of corrosive liquids are also available. They also open automatically when the vapour pressure builds up inside to allow vapours to escape and prevent rupture.

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Hazard Recognition

• Handling Corrosive Materials:– Some of the reasons why containers rupture :

• Heat can cause vapour levels inside a sealed container to build up to the point where the container bursts.

• Air or inert gas pressure used to empty the drum may cause weakened or damaged drums to burst.

• Chemicals stored in a metal drum might react with the metal and form hydrogen gas, which could ignite when the drum is opened.

• The drum may not have been cleaned thoroughly before it was filled. If the previously-stored chemical is incompatible with the corrosive, chemical reactions could cause the drum to explode.

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Hazard Recognition

• Handling Corrosive Materials:– Handle corrosive materials carefully:

• Dispense from only one container at a time. • Finish all the dispensing of one material before starting to

dispense another. • Ensure containers are closed after dispensing. • Handle corrosives so that dusts, mists, vapours, or fumes do

not get into the air.• Be especially careful when transferring from larger containers

into smaller ones. Many injuries have been caused by spillage from open, unstable, or breakable containers during material transfer.

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– Handle corrosive materials carefully:• If liquid corrosives are stored in drums, use a corrosion-

resistant drum pump for transferring liquids into other containers.

• Do not transfer liquids by pressurizing their usual shipping containers with air or inert gas as ordinary drums and barrels may be damaged by the pressure.

• Never pipette corrosive liquids by mouth. Use a pipette bulb instead.

• Transfer corrosive solids using tools like scoops or shovels that are corrosion resistant.

• Always wear the correct Personal Protective Equipment (PPE)

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– Adding water to corrosive materials:• Sometimes a job requires mixing corrosives are mixed with

water. • Many corrosive materials, both liquid and solid, generate large

amounts of heat when they are mixed with water. This can cause the solution to froth and boil or even to erupt violently from the container. For example, a glass of water thrown into a bucket of concentrated sulfuric acid is converted instantly to steam which will eject the entire contents of the bucket into the air.

• Always add corrosives to water, slowly, in small amounts, with frequent stirring.

• Always use cold water.

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– Safe disposal of waste material:• "Empty" drums, bottles and other containers often have

hazardous corrosive residues inside them. Never use these "empty" containers for anything else, no matter how clean they seem to be. Always treat them as corrosive wastes.

• It may be possible to safely decontaminate "empty" containers but expert advice must be obtained from the chemical manufacturer or supplier.

• Never dispose of corrosives down sinks or drains that connect to storm water drains or sewers.

• Dispose of corrosives according to the manufacturer's or supplier's directions, or through specialist approved hazardous waste collection and disposal companies.

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– The importance of good housekeeping, maintaining equipment and personal cleanliness :

• Maintain cleanliness and order at all times in the workplace:– Clean up any spills and buildups of corrosives promptly and

safely. – Properly dispose of unlabelled or contaminated chemicals. – Remove empty containers at once from work areas. – Ensure that all containers for waste are properly marked and

easily located. • Regular effective maintenance of equipment is important in

preventing leaks or emissions of corrosives into the workplace:– Ensure that maintenance personnel know the possible hazards

of the materials to which they might be exposed. – Develop and implement special procedures and precautions that

are be needed before prior to working on equipment.

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– The importance of good housekeeping, maintaining equipment and personal cleanliness continued:

• Personal cleanliness is a very important way of protecting personnel working with hazardous chemicals.

– Wash hands before eating, drinking, smoking or going to the toilet.

– Remove and clean contaminated clothing for laundering before wearing it again, or discard it.

– Do not smoke, drink or eat in any areas where hazardous chemicals are present.

– Store food in uncontaminated areas. – Avoid touching yourself with contaminated hands. – Clean yourself thoroughly at the end of the workday.

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– Personal Protective Equipment (PPE):• Avoid Skin Contact

– Wear protective gloves, aprons, boots, hoods, or other clothing depending on how much chance there is of skin contact. This clothing must be made of materials that resist penetration or damage by the chemical. The MSDS should recommend appropriate materials.

• Protect Eyes and Face – Always wear eye protection when working with corrosives.

Although ordinary safety glasses provide some protection, chemical safety goggles/full face shields are best

• Avoid Breathing Corrosive Vapours, Fumes, Dusts or Mists – If respirators are required for breathing protection, there must be

a written respiratory protection procedure to follow.

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– In the event of an emergency:• Evacuate the area at once if you are not trained to handle the

problem or if it is clearly beyond your control. • Alert other people in the area to the emergency. • Call the fire/emergency response department immediately. • Report the problem to the people responsible for handling

emergencies where you work. • Obtain first aid if you have been exposed to harmful

chemicals.• Most workplace injuries caused by common corrosives, such

as acids and bases, result from accidental skin or eye contact. The first aid for these injuries usually involves flooding the contaminated area with large amounts of water. Emergency eyewash stations and safety showers should be present wherever accidental exposure to corrosives might occur.

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– A summary the basic safety procedures concerning corrosives:

• Obtain and read the Material Safety Data Sheets (MSDSs) for all of the materials used.

• Promote awareness of all of the hazards (fire/explosion, health, chemical reactivity) of the corrisive materials used.

• Store corrosives in suitable labelled containers away from incompatible materials in a cool dry areas.

• Store, handle, and use corrosives in well ventilated areas.• Dispense corrosives carefully. • Keep containers closed when not in use. • Handle containers safely to avoid damaging them.

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– A summary the basic safety procedures concerning corrosives continued:

• Always stir corrosives slowly and carefully into cold water when the job requires mixing corrosives and water.

• Practice good housekeeping, personal cleanliness and equipment maintenance.

• Wear the prescribed personal protective equipment for each particular job.

• Ensure that all employees know how to handle emergencies (fires, spills, personal injury) involving the corrosive materials used

• Handle and dispose of corrosive wastes in accordance with the written safe work procedures.

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Section 6

Personal Protective Equipment (PPE)

105


Section 6

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• Why have a PPE Programme?– The objective of the Personal Protective Equipment

(PPE) Program is to protect employees from the risk of injury by creating a barrier against workplace hazards.

• The Basics of a PPE Programme:– Using personal protective equipment requires hazard

awareness and training on the part of the user.– Employees must be aware that the equipment alone

does not eliminate the hazard.

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• Categories of PPE– Eye & Face Protection– Respiratory– Head Protection– Foot Protection– Electrical Protection– Hand Protection– Hearing Protection– Protective clothing– Protective ointments– Shields– Restraints

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• Where and when is PPE required?– PPE is required wherever the following conditions are

encountered that are capable of causing injury or impairment by being absorbed, inhaled, or physically contacted:

• Process hazards• Environment hazards,• Chemical hazards,• Radiological hazards, or• Mechanical irritants/hazards

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• What is required?– An employer has an obligation to provide protective

equipment PPE, including personal protective equipment for eyes, face, head, extremities and protective clothing.

– The employer must ensure employees use PPE.– The employer must ensure that PPE is maintain in a

sanitary and reliable condition.– The employer is obligated to provide and to pay for

PPE required by the company for the worker to do his or her job safely and in compliance with regualtionsand standards.

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• PPE design:– All PPE must be of safe design and construction and

effective for the work to be performed.

• Proper use:– All PPE must be worn and used in a manner which will

make full use of its protective qualities.

• What should not be worn?– Rings, wristwatches, earrings, bracelets, and other

jewelry must not be worn if it is possible for it to come into contact with power driven machinery or electric circuitry.

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• The Six-Step Assessment Process:1. Conduct a Survey:

• The most effective strategy for surveying the work area is to use a team of individuals conduct the survey.

• The team should be multidisciplinary to include the necessary range of expertise and experience.

• The team should be formally structured.• The work of the team should be formally documented.• It is often useful to break down the survey into sections of

the plant, especially in the case of large operations.

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• The Six-Step Assessment Process continued:2. Determine sources of hazards:

• During the walk about survey the assessment team should determine if any of the following hazard sources exist:– Sources of motion: machinery or processes where any movement of

tools, machine elements or particles could cause injuries.– Sources of high temperatures that could result in burns, eye injury etc.– Chemicals that could contact skin and eyes.– Sources of hazardous atmospheres.– Sources of radiation: welding, brazing, GLC radioactive sources etc.– Sources of falling objects or potential for dropping objects.– Sources of sharp objects which might pierce the feet or cut the hands.– Sources of rolling or pinching objects which could crush the feet.– Layout of workplace and location of co-workers.– Electrical hazards.

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• The Six-Step Assessment Process continued:3. Organize the data:

• Following the walk about survey, it is necessary to organize the data and information for use in the assessment of the identified hazards.

• The data should be presented in a structured format that to facilitates the analysis of the hazards in the workplace to enable proper selection of the PPE.

• In addition historical injury/accident/incident data should be reviewed to help identify potential problem areas.

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• The Six-Step Assessment Process continued:4. Analyze the data:

• Having gathered and organized the data from the survey of the workplace, an estimate of the potential for injuries should be made. Each of the basic hazards categories should be reviewed to determine the:– Nature of the hazard– Degree of risk– Seriousness or severity of potential injury– Possibility of exposure to several hazards simultaneously.

• A formal structured hazard analysis process should be used.

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• The Six-Step Assessment Process continued:5. Select the PPE:

• After completing the hazard assessment it's time to select the right PPE for the job: To do this most effectively it is important to:– Become familiar with the potential hazards and the type of protective

equipment that are available and understand what protection theyprovide

– Compare the hazards associated with the environment, i.e. impactvelocities, masses, radiation intensities etc. with the capabilities of the available PPE

– Involve employees in the selection process– Select PPE which ensures a level of protection greater than the

minimum required to protect employees from the hazards– Fit the user with the protective device and give instructions on care and

use of the PPE. – Make employees aware of all warning labels for and limitations of their

PPE.

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• The Six-Step Assessment Process continued:6. Select the PPE:

• It is the responsibility of management to regularly reassess the workplace hazard situation:– By identifying and evaluating new PPE as it becomes available– Whenever there are machine, material or process changes and

or modifications– By reviewing accident records– By re-evaluating the suitability of previously selected PPE.

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• PPE Training Requirements:– The minimum training requirements are:

• When PPE is necessary• What PPE is necessary• How to properly don, adjust, wear and remove PPE;• The limitations of the PPE• The proper care, maintenance, useful life and disposal of the

PPE.• Why PPE use is important.

– Whenever employees are trained on how to use PPE they should be educated on PPE principles, technology etc. at the same.

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• PPE Training Requirements:– The need to demonstrate PPE:

• Before an employee is allowed to do undertake any work requiring PPE the employer must require each affected employee to:

– Demonstrate an understanding of the minimum training elements (the what, when, and how of PPE use) and

– Demonstrate the ability to use PPE properly.

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• PPE Training Requirements:– The need to demonstrate PPE:

• Before an employee is allowed to do undertake any work requiring PPE the employer must require each affected employee to:

– Demonstrate an understanding of the minimum training elements (the what, when, and how of PPE use) by way of a test/quiz and

– Demonstrate the ability to use PPE properly.

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• PPE Training Requirements:– The level of knowledge of employees who have

received training should be measured by conducting an oral or preferably written test similar to the short quiz below:1. What are the PPE required for your particular job?2. When is the PPE required to be used in your job?3. What are the possible defects your PPE might have?4. How do you properly care for and maintain/store your PPE?5. What is the useful life of your PPE?6. From what hazards does the PPE protect you?

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• PPE Training Requirements:– The basic steps in On The Job training are:

1. Introduction2. Trainer show and tell:

– The trainer first explains and demonstrates safe work proceduresassociated with the task

3. Trainee tell and show:• The trainer has the trainee carry out the procedure

4. Conclusion;– Re-emphasize the importance of the procedure and it fits into the

overall process. Tie the training to accountability.5. Document:

– Training register – attendees and training – Testy results – Trainer certifies trainee has demonstrated adequate knowledge and

skill to complete the procedure.

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• Eye and Face Protection:– What contributes to eye injuries at work?

• Not wearing eye protection• Wearing the wrong kind of eye protection for the job.

– What causes eye injuries?• Flying particles• Contact with chemicals• Other accidents caused by objects swinging from a fixed or

attached position, like tree limbs, ropes or chains • Tools which were pulled into the eye while the worker was

using them.

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• Eye and Face Protection:– Glasses:

• Protective eyeglasses are made with safety frames, tempered glass or plastic lenses, temples and side shields.

• They provide eye protection from moderate impact and particles encountered in job tasks such as carpentry, woodworking, grinding, scaling, etc.

• Safety glasses are also available in prescription form for those persons who need corrective lenses.

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• Eye and Face Protection:– Goggles:

• Vinyl framed goggles of soft pliable body design provide adequate eye protection from many hazards.

• Goggles are available with clear or tinted lenses, perforated, port vented, or non-vented frames.

• Single lens goggles provide similar protection to safety glasses and may be worn in combination with spectacles or corrective

• lenses to insure protection along with proper vision. • Welders goggles provide protection from sparking, scaling, or

splashing metals and harmful light rays. Lenses are impact resistant and are available in graduated shades of filtration.

• Grinders goggles provide eye protection from flying particles. The dual protective eye cups house impact resistant clear lenses with individual cover plates.

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• Eye and Face Protection:– Face Shields:

• These normally consist of an adjustable headgear and face shield of tinted/transparent acetate or polycarbonate materials, or wire screen.

• Face shields are available in various sizes, tensile strength, impact/heat resistance and light ray filtering capacity.

• Face shields will be used in operations when the entire face needs protection and should be worn to protect eyes and face against flying particles, metal sparks, and chemical/biological splash.

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• Eye and Face Protection:– Welding Shields:

• These shield assemblies normally consist of a vulcanized fiber, plastic or glass fiber body, a ratchet/button type adjustable headgear or cap attachment and a filter and cover plate holder.

• These shields will be provided to protect workers’ eyes and face from infrared or radiant light burns, flying sparks, metal spatter and slag chips encountered during welding, brazing, soldering, resistance welding, bare or shielded electric arc welding and oxyacetylene welding and cutting operations.

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• Eye and Face Protection:– Eye and face PPE must be distinctly marked to

facilitate identification of the manufacturer.– Lasers:

• Employees whose occupation or assignment requires exposure to laser beams should be provided with laser safety goggles which will protect them for the specific wavelength of the laser and be of optical density adequate for the energy involved.

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• Respiratory Protection:– If hazardous atmospheres are generated by any of

the following then it must be controlled to prevent disease to workers:• Fogs/mists• Fumes• Gases• Smokes• Sprays• Vapours• Grits/particulate matter/powders.

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• Respiratory Protection:– The first priority is to try to engineer out the respiratory hazard.– Examples of acceptable engineering controls to eliminate or

reduce atmospheric hazards include:• Enclosure or confinement of the operation,• General and local ventilation, and• Substitution of less toxic materials

– When effective engineering controls are not feasible, or while they are being instituted, the employer must provide appropriaterespirators to protect the health of the employee, and establishand maintain an effective respiratory protective programme

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• Respiratory Protection:– Respiratory Protection Program Requirements:

• Procedures for selecting respirators for use in the workplace• Medical evaluations of employees required to use respirators• Fit testing procedures for tight-fitting respirators• Procedures for proper use of respirators in routine and reasonably

foreseeable emergency situations• Procedures and schedules for cleaning, disinfecting, storing, inspecting,

repairing, discarding, and otherwise maintaining respirators• Procedures to ensure adequate air quality, quantity, and flow of breathing

air for atmosphere-supplying respirators• Training of employees in the respiratory hazards to which they are

potentially exposed during routine and emergency situations• Training of employees in the proper use of respirators, including putting on

and removing them, any limitations on their use, and their maintenance• Procedures for regularly evaluating the effectiveness of the program.

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• Respiratory Protection:– Respiratory Equipment Inspection requirements:

• Frequent inspections must be conducted by qualified persons in order to assure that respirators are properly selected, used, cleaned and maintained

• Replace any worn or deteriorated parts• Inspect self-contained breathing apparatus monthly and after use• Make sure air and oxygen cylinders are fully charged according to

the manufacturer's instructions• Make sure that the regulator and warning devices function properly.• Check the tightness of connections and the condition of the face

piece, headbands, valves, connecting tube, and canisters.• Inspect rubber or elastomer parts for pliability and signs of

deterioration• A record must be kept of inspection dates and findings for

respirators maintained for emergency use• Keep written records of all inspections.

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• Respiratory Training:– For an effective respirator program, it's essential that

supervisors and workers be properly instructed by a competent person in:• Selecting appropriate protection• Donning and removing• Using respirators• Storing and maintaining respirators• Detecting defects• Proper fitting• Testing for proper seal

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• Selecting Respirators:– It is essential to select and provide an appropriate

respirator based on the respiratory hazard(s) to which the worker is exposed in the workplace and user factors that affect respirator performance and reliability.

– The employer must identify and evaluate the respiratory hazard(s) in the workplace; this evaluation must include:• A reasonable estimate of employee exposures to respiratory

hazard(s), and • An identification of the contaminant's chemical state and

physical form.

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• Selecting Respirators continued:– Where the employer cannot identify or reasonably

estimate the employee exposure, the employer must consider the atmosphere to be immediately dangerous to life and health (IDLH).

– IDLH means an atmosphere that poses an immediate threat to life, would cause irreversible adverse health effects, or would impair an individual's ability to escape from a dangerous atmosphere.

– Only use certified respirators.

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• Respirators for atmospheres that are IDLH:– The employer must provide the following respirators

for employee use in IDLH atmospheres:• A full face piece pressure demand certified SCBA certified

for a minimum service life of thirty minutes, or• A combination full face piece pressure demand supplied air

respirator (SAR) with auxiliary self-contained air supply.

– Respirators provided only for escape from IDLH atmospheres must be certified for escape from the atmosphere in which they will be used.

– All oxygen-deficient atmospheres must be considered IDLH.

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• Respirators for atmospheres that not IDLH:– The employer must provide a respirator that is

adequate to protect the health of the employee and ensure compliance with all statutory and regulatory requirements, under routine and reasonably foreseeable emergency situations.

– The respirator selected must be appropriate for the chemical state and physical form of the contaminant.

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• Respirators for atmospheres that not IDLH contd:– For protection against gases and vapours the employer must

provide an atmosphere-supplying respirator, or an air purifying respirator, provided that:• The respirator is equipped with an end-of-service-life indicator

(ESLI) certified for the contaminant; or• If there is no ESLI appropriate for conditions in the employer's

workplace, the employer implements a change schedule for canisters and cartridges that is based on objective information or data that will ensure that canisters and cartridges are changed before the end of their service life

• The employer must describe in the respirator program the information and data relied upon and the basis for the canister and cartridge change schedule and the basis for reliance on the data.

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• Respirators for atmospheres that not IDLH contd:– For protection against particulates, the employer

must provide:• An atmosphere-supplying respirator; or• An air-purifying respirator equipped with a filter certified as a

high efficiency particulate air (HEPA) filter, or A• An air-purifying respirator equipped with a filter certified for

the specified particulates or• For contaminants consisting primarily of particles with mass

median aerodynamic diameters (MMAD) of at least 2 micrometers, an air-purifying respirator equipped with any filter certified for particulates.

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• Using respirators:– Written procedures:

• It is important to develop standard procedures for respirator use. These should include:– All information and guidance necessary for their proper

selection, use and care – Possible emergency and routine uses of respirators.

– Physical ability to use:• Ensure that employees are not assigned to tasks requiring

respirators unless they are physically able to adequately perform the work and use the equipment.

• If there is any question or concern about an employee using the respirator, a local medical doctor must determine what health and physical conditions are pertinent.

140


• Using respirators continued:– Face Seals:

• Do not wear respirators when conditions prevent a good face seal. Such conditions may be a growth of beard, temple pieces on glasses etc.

• Maintaining respirators:– Respirators must be stored in a convenient, clean, and sanitary

location.– The programme for the maintenance and care of respirators

must include the following basic services:• Inspection for defects (including a leak check)• Cleaning and disinfecting,• Repair• Storage

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• Medical evaluation procedures:– Using a respirator may place a physiological burden

on employees that varies with the type of respirator worn, the job and workplace conditions in which the respirator is used, and the medical status of the employee.

– The employer must provide a medical evaluation to determine the employee's ability to use a respirator, before the employee is fit tested or required to use the respirator in the workplace.

– The employer must ensure that there are routine follow-up medical examinations.

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• Head Protection:– There are primarily two situations when employees must wear

protective helmets:• Falling objects• Electrical hazards

– Falling objects:• Wherever there is a potential in the workplace for injury to the head

from falling objects, the employer must make sure that each affected employee wears a protective helmet.

• Some examples of work that might require helmets to protect fromfalling objects include:– Working below other workers who are using tools and materials which

could fall– Working around or under conveyor belts which are carrying parts or

materials– Working below machinery or processes which might cause material or

objects to fall.

143


• Head Protection continued:– Electrical hazards :

• Whenever an employee works near exposed electrical conductors which could contact the head, the employer must make sure that a protective helmet designed to reduce electrical shock hazard is worn by the employee.

– Some selection guidelines for head protection:• Class A helmets:

– In addition to impact and penetration resistance, this class of helmet provides electrical protection from low-voltage conductors (they are proof tested to 2,200 volts).

• Class B helmets:– In addition to impact and penetration resistance, this class of

helmet provides electrical protection from high-voltage conductors (they are proof tested to 20,000 volts).

144


• Hand Protection:– Hazards requiring hand protection include:

– Chemical hazards which might expose the employee to the following:» Absorption of harmful substances» Chemical burns» Rashes

– Other hazards that could injure their hands including:» Cuts or lacerations;» Abrasions» Punctures» Thermal burns» Harmful temperature extremes

145


• Hand Protection continued:– Selection:

• Employers should work closely with their PPE suppliers to selectappropriate hand protection based on an evaluation of the performance characteristics of the hand protection. Specifically the employer needs to look at the following:– Specific task(s) being performed– Environmental conditions present,– Duration of hand protection use while performing the task,– The actual hazards– The potential hazards.

• The work activities of the employee should also be studied to determine the:– Degree of dexterity required,– Duration the task,– Frequency of the task,– Degree of exposure of the hazard– The physical stresses that will be applied.

146


• Hand Protection continued:– The following is a guide to the most common types of protective work

gloves and the types of hazards they can guard against:• Disposable Gloves. Disposable gloves, usually made of light-weight

plastic, can help guard against mild irritants.• Fabric Gloves. Made of cotton or fabric blends are generally used to

improve grip when handling slippery objects. They also help insulate hands from mild heat or cold.

• Leather Gloves. These gloves are used to guard against injuries from sparks or scraping against rough surfaces. They are also used incombination with an insulated liner when working with electricity.

• Metal Mesh Gloves. These gloves are used to protect hands form accidental cuts and scratches. They are used most commonly by persons working with cutting tools or other sharp instruments.

• Aluminized Gloves. Gloves made of aluminized fabric are designed to insulate hands from intense heat. These gloves are most commonly used by persons working molten materials or ovens/kilns.

• Chemical Resistance Gloves. These gloves may be made of rubber, neoprene, pvc, etc. The gloves protect hands from corrosives, oils, and solvents.

147


• Foot Protection:– The employer must make sure that each affected employee

uses protective footwear when working in areas where there is a danger of foot injuries due to:• Falling or rolling objects• Objects piercing the sole• Where feet are exposed to electrical hazards

– Steel-Reinforced Safety Shoes:• These shoes are designed to protect feet from common hazards

such as falling or rolling objects, cuts, and punctures. • The entire toe box and insole are reinforced with steel, and the

instep is protected by steel, aluminum, or plastic materials.• Safety shoes are also designed to insulate against temperature

extremes and may be equipped with special soles to guard againstslip, chemicals, and/or electrical hazards

148


• Foot Protection continued:– Safety Boots:

• Safety boots offer more protection than safety shoes when splash or spark hazards (chemicals, molten materials) are present.

• When working with corrosives, caustics, cutting oils, and petroleum products, neoprene or nitrile boots are often required to prevent penetration.

• Foundry or "Gaiter" style boots feature quick-release fasteners or elasticized insets to allow speedy removal should any hazardous substances get into the boot itself.

• When working with electricity, special electrical hazard boots are available and are designed with no conductive materials other than the steel toe (which is properly insulated)

149


• Electrical Protection Equipment:– Electrical protective equipment includes the following:

– Insulating blankets– Covers– Gloves– Sleeves made of rubber– etc.

– All electrical protective equipment made of rubber must conform with the relevant safety standards and specifications covering Voltages

– To make sure electrical protective equipment actually performs as designed, it must be inspected for damage before each day's use and immediately following any incident that can reasonably be suspected of having caused damage.

150


• Electrical Protection Equipment continued:– Insulating equipment must not be used if any of the following defects

are detected:• A hole, tear, puncture, or cut• Ozone cutting or ozone checking (the cutting action produced by ozone on

rubber under mechanical stress into a series of interlacing cracks);• An embedded foreign object• Any of the following texture changes: swelling, softening, hardening, or

becoming sticky or inelastic• Any other defect that damages the insulating properties.

– Insulating equipment found to have other defects that might affect its insulating properties must be removed from service and returned for testing.

– It must be cleaned as needed to remove foreign substances, and stored in such a location and in such a manner as to protect it from light, temperature extremes, excessive humidity, ozone, and other injurious substances and conditions.

151


• Electrical Protection Equipment continued:– Electrical protective equipment must be subjected to

periodic electrical tests.– The test method used must reliably indicate whether

the insulating equipment can withstand the voltages involved.

– Repaired insulating equipment must be retested before it may be used by employees.

– The employer must certify that equipment has been tested in accordance with the requirements of the relevant standard.

152


• Working at Elevated Positions: Fall Protection Equipment:– Fall protection equipment is required when:

• Working on unguarded surfaces more than 3m above a lower level, or

• Working at any height above dangerous equipment.

– Fall protection may be categorized into two general categories:• Fall restraint systems• Fall arrest systems.

153


• Working at Elevated Positions: Fall Protection Equipment continued:– Fall restraint systems are designed to prevent an

employee from falling. They include:• Guardrails• Personal fall restraint systems etc.

– Fall arrest systems are designed, not to necessarily prevent a fall, but to stop a fall once initiated. At a minimum they must be rigged so that the employee will not free fall more than 2m , nor contact any lower level. They include:• Personal fall arrest systems• Safety nets.

154


• Fall Protection Equipment continued:– Inspecting fall protection equipment:

• All lifelines, lanyards, body belts and harnesses must be periodically inspected by a competent person charge and prior to each use as an added safety factor.

– Why use a full body harness?• Arrest forces are focused on the point of

attachment which is usually the lower back• The full body harness is required for personal fall

arrest systems because it is designed to spread the arrest forces throughout the entire upper body.

• The attachment is at the upper back, with straps attaching at various point in both the upper and lower part of the body. Consequently, arrest forces are spread over a much wider area.

155


• Hearing protectors:– The employer must administer a continuing, effective

hearing conservation programme whenever employee noise exposures equal or exceed an 8-hour time-weighted average sound level (TWA) of 85 decibels measured on the A scale.

– There are basically four types of hearing protectors:• Molded earplugs• Custom-molded earplugs• Self-molded earplugs• Ear muffs.

156


• Hearing protectors continued:– Molded earplugs:

• These are usually made of plastic or silicone rubber. They are available in a variety of shapes and sizes and are usually characterized by one or more ribs or contours.

• They are considered multiple use and therefore they must be cleaned and properly stored after each use.

– Custom-molded earplugs:• These are generally made of plastic and are designed from

a molded wax insert of the wearer's ears. • They are considered multiple use but cannot be switched

ear to ear.

157


• Hearing protectors continued:– Self-molded earplugs :

• These are generally made of plastic foam and are molded or formed by the wearer

• Generally one size fits all and they may be either single or multiple use.

– Ear muffs:• These are designed to be multiple use and may be designed

to be worn with the harness over or behind the head, or below the chin

• They are generally more comfortable, but usually provide less noise reduction, thus less protection, than ear plugs.

158


• Hearing protectors continued:– Education and Training :

• The employer must provide training in the use and care of all hearing protectors provided to employees who are exposed to noise at or above an 8-hour time-weighted average of 85 decibels, and must make sure employees participate in the programme.

• Education tells employees the "why" which increases understanding and includes information on:– The effects of noise on hearing– The purpose of hearing protectors– The advantages, disadvantages of different types– Attenuation of various types– The purpose of audiometric testing, and an explanation of the test

procedures.• The employer must also make sure that each employee

demonstrates the ability to use and care hearing protectors.

Section 7

Safety Inspections & Audits

159

Safety Inspections and Audits

Section 7

160


• Definition of an Audit:– It is a systematic, periodical evaluation of a

company’s safety organisation, performance and systems against pre-determined standards

– The audit should also focus on the organisational structure, responsibilities, practices, plans, procedures, processes and resources for implementing maintenance management

161


• The Seven Key Programme Elements to Audit:1. Management commitment2. Employee and management accountability3. Employee involvement4. Hazard identification and control5. Incident and accident investigation6. Employee Training7. Periodic program evaluation

162


• Audit & Inspection Checklists:– Safety & Health Programme:

• Is there an active safety and health program in operation that deals with general safety and health program elements as well as management of hazards specific to each worksite?

• Is one person clearly responsible for the overall activities of the safety and health programme?

• Is their a a safety committee or group made up of management and labour representatives that meets regularly and reports in writing on its activities?

• Is there a working procedure for handling in-house employee complaints regarding safety and health?

163


• Audit & Inspection Checklists:– Safety & Health Programme continued:

• Are employees advised of the successful effort and accomplishments that have made in assuring they will have a workplace that is safe and healthy?

• Is one person clearly responsible for the overall activities of the safety and health programme?

• Is their a a safety committee or group made up of management and labour representatives that meets regularly and reports in writing on its activities?

• Is there a working procedure for handling in-house employee complaints regarding safety and health?

• Are there incentives for employees or workgroups who have excelled in reducing workplace injuries/illnesses?

164


• Audit & Inspection Checklists:– PPE:

• Is the employer assessing the workplace to determine if hazards that require the use of personal protective equipment (for example, head, eye, face, hand, or foot protection) are present or are likely to be present?

• If hazards or the likelihood of hazards are found, are employers selecting and having affected employees use properly fitted personal protective equipment suitable for protection from these hazards?

• Is there a safety committee or group made up of management and labour representatives that meets regularly and reports in writing on its activities?

• Has each affected employee been trained on PPE procedures i.e. what PPE is necessary for a job task, when they need it, and how to properly adjust it?

165


• Audit & Inspection Checklists:– PPE continued:

• Is the employer assessing the workplace to determine if hazards that require the use of personal protective equipment (e.g. head, eye, face, hand, or foot).

• Are protective goggles or face shields provided and worn where there is any danger of flying particles, dangerous cehmicals or corrosive materials?

• Are approved safety glasses required to be worn at all times in areas where there is a risk of eye injuries such as punctures, abrasions, contusions or burns?

• Are protective gloves, aprons, shields, or other means provided and required where employees could be cut or where there is reasonably anticipated exposure to corrosive liquids, chemicals, blood, or other potentially infectious materials?

166



• Are hard hats provided and worn where danger of falling objects exists?

• Are hard hats inspected periodically for damage to the shell and suspension system?

• Is appropriate foot protection required where there is the risk of foot injuries from hot, corrosive, or poisonous substances, falling objects, crushing or penetrating actions?

• Are approved respirators provided for regular or emergency use where needed?

• Is all protective equipment maintained in a sanitary condition and ready for use?

167



• Are there eye wash facilities and quick drench showers within the work area where employees are exposed to injurious corrosive materials?

• Where special equipment is needed for electrical workers, is it available?

• Where food or beverages are consumed on the premises, are they consumed in areas where there is no exposure to toxic material, blood, or other potentially infectious materials?

• Is protection against the effects of occupational noise exposure provided when sound levels exceed the legislated maximum?

168



• Are there adequate work procedures, protective clothing and equipment provided and used when cleaning up spilled toxic or otherwise hazardous materials or liquids?

• Are there appropriate procedures in place for disposing of or decontaminating PPE contaminated with, or reasonably anticipated to be contaminated with, blood or other potentially infectious or toxic materials?

169


• Audit & Inspection Checklists:– Flammable and Combustible Materials:

• Are combustible scrap, debris, and waste materials (oily rags, etc.) stored in separate covered metal receptacles and removed from the worksite promptly?

• Is proper storage practiced to minimize the risk of fire including spontaneous combustion?

• Are approved containers and tanks used for the storage and handling of flammable and combustible liquids?

• Are all connections on drums and combustible liquid piping, vapour and liquid tight?

• Are all flammable liquids kept in closed containers when not in use?

• Are bulk drums of flammable liquids grounded and bonded to containers during dispensing?

170


• Audit & Inspection Checklists:– Flammable and Combustible Materials continued:

• Do storage rooms for flammable and combustible liquids have explosion-proof lights and other electrical fittings?

• Do storage rooms for flammable and combustible liquids have mechanical or natural/convection ventilation?

• Is liquefied petroleum gas stored, handled, and used in accordance with safe practices and standards?

• Are liquefied petroleum storage tanks guarded to prevent damage from vehicles?

• Are all solvent wastes and flammable liquids kept in fire-resistant, covered containers until they are removed from the worksite?

171



• Is vacuuming used whenever possible rather than blowing or sweeping combustible dust?

• Are firm separators placed between containers of combustibles or flammables, when stacked one upon another, to assure their support and stability?

• Are fuel gas cylinders and oxygen cylinders separated by distance, and fire-resistant barriers, while in storage?

• Are fire extinguishers selected and provided for the types of materials in areas where they are to be used? – Class A Ordinary combustible material fires – Class B Flammable liquid, gas or grease fires – Class C Energized-electrical equipment fires.

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• Are extinguishers free from obstructions or blockage? • Are all extinguishers serviced, maintained and tagged at

intervals not to exceed 1 year? • Are all extinguishers fully charged and in their designated

places? • Are "NO SMOKING" and “NO NAKED FLAME” signs posted

where appropriate in areas where flammable or combustible materials are used or stored?

• Are safety cans used for dispensing flammable or combustible liquids at a point of use?

173



• Are all spills of flammable or combustible liquids cleaned up promptly?

• Are storage tanks adequately vented to prevent the development of excessive vacuum or pressure as a result of filling, emptying, or atmosphere temperature changes?

• Are storage tanks equipped with emergency venting that will relieve excessive internal pressure caused by fire exposure?

• Are "NO SMOKING" and “NO NAKED FLAME” rules enforced in areas involving storage and use of hazardous materials?

174


• Audit & Inspection Checklists:– Hand Tools:

• Are all tools and equipment (both company and employee owned) used by employees at their workplace in good condition?

• Are appropriate handles used on files and similar tools? • Are employees made aware of the hazards caused by faulty

or improperly used hand tools? • Are appropriate safety glasses, face shields, etc. used while

using hand tools or equipment which might produce flying materials or be subject to breakage?

• Are tool handles wedged tightly in the head of all tools? • Are tools stored in dry, secure locations where they won't be

tampered with?

175


• Audit & Inspection Checklists:– Power Operated Tools and Equipment:

• Are grinders, saws and similar equipment provided with appropriate safety guards?

• Are power tools used with the correct shield, guard, or attachment, recommended by the manufacturer?

• Are portable circular saws equipped with guards?• Are rotating or moving parts of equipment guarded to

prevent physical contact? • Are all cord-connected, electrically operated tools and

equipment effectively grounded?• Are effective guards in place over belts, pulleys, chains,

sprockets, on equipment such as concrete mixers, and air compressors?

176


• Audit & Inspection Checklists:– Power Operated Tools and Equipment continued:

• Are portable fans provided with full guard screens?• Is hoisting equipment available and used for lifting heavy

objects, and are hoist ratings and characteristics appropriate for the tasks?

• Are ground-fault circuit interrupters (earthe leakgedetectors) provided on all electrical single phase (15 ampere circuits), including temporary supplies used during periods of construction?

• Are pneumatic and hydraulic hoses on power operated tools checked regularly for deterioration or damage?

177


• Audit & Inspection Checklists:– Lock-out/Tag-out Procedures:

• Is all machinery or equipment capable of movement, required to be de-energized or disengaged and locked-out during cleaning, servicing, adjusting or setting up operations, whenever required?

• Where the power disconnecting means for equipment does not also disconnect the electrical control circuit: – Are the appropriate electrical enclosures identified? – Is means provided to assure the control circuit can also be

disconnected and locked-out? • Is the locking-out of control circuits in lieu of locking-out

main power disconnects prohibited?

178


• Audit & Inspection Checklists:– Lock-out/Tag-out Procedures continued:

• Are all equipment control valve handles provided with a means for locking-out?

• Are appropriate employees provided with individually keyed personal safety locks?

• Are employees required to keep personal control of their key(s) while they have safety locks in use?

• Is it required that only the employee exposed to the hazard, place or remove the safety lock?

• Is it required that employees check the safety of the lock-out by attempting a startup after making sure no one is exposed?

179


• Audit & Inspection Checklists:– Lock-out/Tag-out Procedures continued:

• Is there a means provided to identify any or all employees who are working on locked-out equipment by their locks or accompanying tags?

• Are a sufficient number of accident preventive signs or tags and safety padlocks provided for any reasonably foreseeable repair emergency?

• Does the lock-out procedure require that stored energy (mechanical, hydraulic, air, etc.) be released or blocked before equipment is locked-out for repairs?

• In the event that equipment or lines cannot be shut down, locked-out and tagged, is a safe job procedure established and strictly followed?

180


• Audit & Inspection Checklists:– Confined Spaces:

• Are confined spaces thoroughly emptied of any corrosive or hazardous substances, such as gases, acids or caustics, before entry?

• Are all lines to a confined space, containing inert, toxic, flammable, or corrosive materials valved off and blanked or disconnected and separated before entry?

• Is either natural or mechanical ventilation provided prior to confined space entry?

• Are appropriate atmospheric tests performed to check for oxygen deficiency, toxic substances and explosive concentrations in the confined space before and after entry?

181


• Audit & Inspection Checklists:– Confined Spaces continued:

• Are confined spaces thoroughly emptied of any corrosive or hazardous substances, such as gases, acids or caustics, before entry?

• Is adequate illumination provided for the work to be performed in the confined space?

• Is there an assigned safety standby employee outside of the confined space. when required, whose sole responsibility is to watch the work in progress, sound an alarm if necessary, and render assistance?

• Is the standby employee appropriately trained and equipped to handle an emergency?

182



• Is the standby employee or other employees prohibited from entering the confined space without lifelines and respiratory equipment if there is any question as to the cause of an emergency?

• Is approved respiratory equipment required if the atmosphere inside the confined space cannot be made acceptable?

• Is all portable electrical equipment used inside confined spaces either grounded and insulated, or equipped with ground fault protection?

183



• Before gas welding or burning is started in a confined space, are hoses checked for leaks, compressed gas bottles forbidden inside of the confined space, torches lighted only outside of the confined area and the confined area tested for an explosive atmosphere each time before a lighted torch is to be taken into the confined space?

• If employees will be using oxygen-consuming equipment, such as flame torches and furnaces, in a confined space is sufficient air provided to ensure combustion without reducing the oxygen concentration of the atmosphere below 19.5 percent by volume?

184



• Whenever combustion-type equipment is used in a confined space, are provisions made to ensure the exhaust gases are vented outside of the enclosure?

• Is each confined space checked for decaying vegetation or animal matter which may produce methane?

• Is the confined space checked for possible industrial waste which could contain toxic properties?

• If the confined space is below the ground and near areas where motor vehicles will be operating, is it possible for vehicle exhaust or carbon monoxide to enter the space?

185


• Audit & Inspection Checklists:– Electrical:

• Is compliance with electrical and wiring regulations specified for all contract electrical work?

• When electrical equipment or lines are to be serviced, maintained or adjusted, are necessary switches opened, locked-out and tagged whenever possible?

• Do extension cords being used have a grounding conductor?

• Are electrical appliances such as vacuum cleaners, polishers, and vending machines grounded?

• Are portable electrical tools and equipment grounded or of the double insulated type?

186


• Audit & Inspection Checklists:– Electrical continued:

• Are there electrical installations in hazardous dust or vaporareas? If so, do they comply with the codes for hazardous locations?

• Is the location of electrical power lines and cables (overhead, underground, underfloor, other side of walls) determined before digging, drilling or similar work is begun?

• Is the use of metal ladders prohibited in areas where the ladder or the person using the ladder could come in contact with energized parts of equipment, fixtures or circuit conductors?

• Do all interior wiring systems include provisions for grounding metal parts of electrical raceways, equipment and enclosures?

187


• Audit & Inspection Checklists:– Electrical continued:

• Are all energized parts of electrical circuits and equipment guarded against accidental contact by approved cabinets or enclosures?

• Are all unused openings (including conduit knockouts) in electrical enclosures and fittings closed with appropriate covers, plugs or plates?

• Is each motor disconnecting switch or circuit breaker located within sight of the motor control device?

• Are employees who regularly work on or around energized electrical equipment or lines instructed in the cardiopulmonary resuscitation (CPR) methods?

• Are employees prohibited from working alone on energized lines or equipment ?

188


• Audit & Inspection Checklists:– General Work Environment:

• Is a documented, functioning housekeeping program in place?

• Are all workplaces clean, sanitary, and orderly? • Are work surfaces kept dry or is appropriate means taken to

assure the surfaces are slip-resistant? • Are all spilled hazardous materials or liquids cleaned up

immediately and according to proper procedures? • Is combustible scrap, debris and waste stored safely and

removed from the worksite properly? • Is all regulated waste discarded according to federal, state,

and local regulations?

189


• Audit & Inspection Checklists:– General Work Environment continued:

• Is a documented, functioning housekeeping program in place?

• Are accumulations of combustible dust routinely removed from elevated surfaces including the overhead structure of buildings, etc.?

• Is combustible dust cleaned up with a vacuum system to prevent the dust from going into suspension?

• Is metallic or conductive dust prevented from entering or accumulating on or around electrical enclosures or equipment?

• Are covered metal waste cans used for oily and paint-soaked waste?

190


• Audit & Inspection Checklists:– Walkways:

• Are aisles and passageways kept clear? • Are aisles and walkways marked as appropriate? • Are wet surfaces covered with non-slip materials? • Are holes in the floor, sidewalk or other walking surface

repaired properly, covered or otherwise made safe? • Is there safe clearance for walking in aisles where motorized

or mechanical handling equipment is operating? • Are materials or equipment stored in such a way that sharp

projectives will not interfere with the walkway? • Are aisles or walkways that pass near moving or operating

machinery, welding operations or similar operations arranged so employees will not be subjected to potential hazards?

191


• Audit & Inspection Checklists:– Walkways continued:

• Are aisles and passageways kept clear? • Is adequate headroom provided for the entire length of any

aisle or walkway and if not is restricted headroom clearly demarcated?

• Are standard guardrails provided wherever aisle or walkway surfaces are elevated more than 750 mm above any adjacent floor or the ground?

• Are bridges provided over conveyors and similar hazards? • Are toe boards fitted on all elevated walkways?

192


• Audit & Inspection Checklists:– Floor and Wall Openings:

• Are floor openings and pits guarded by a cover, a guardrail, or equivalent on all sides (except at entrance to stairways or ladders)?

• Are toeboards installed around the edges of permanent floor openings (where persons may pass below the opening)?

• Is the glass in the windows, doors, glass walls, etc., which are subject to human impact, of sufficient thickness and type for the condition of use?

• Are floor or wall openings in fire resistive construction provided with doors or covers compatible with the fire rating of the structure and provided with a self-closing feature when appropriate?

193


• Audit & Inspection Checklists:– Stairs and Stairways:

• Are standard stair rails or handrails on all stairways having four or more risers?

• Do stairs angle no more than 50 and no less than 30 degrees?

• Are step risers on stairs uniform from top to bottom and do the dimensions comply with regulations?

• Are steps on stairs and stairways designed or provided with a surface that renders them slip resistant?

• Where stairs or stairways exit directly into any area where vehicles may be operated, are adequate barriers and warnings provided to prevent employees stepping into the path of traffic?

194


• Audit & Inspection Checklists:– Elevated Surfaces:

• Are surfaces elevated more than 750 mm above the floor or ground provided with standard guardrails?

• Are all elevated surfaces (beneath which people or machinery could be exposed to falling objects) provided with standard 100 mm toe boards?

• Is material on elevated surfaces piled, stacked or racked in a manner to prevent it from tipping, falling, collapsing, rolling or spreading?

• Are bridge plates used when transferring materials between docks and trucks or railway cars?

• Is a permanent means of access and egress provided to elevated storage and work surfaces?

195


• Audit & Inspection Checklists:– Hazard Communication:

• Is there a list of hazardous substances used in the workplace?

• Is there a written hazard communication program dealing with Material Safety Data Sheets (MSDS), labeling, and employee training?

• Is each container for a hazardous substance (i.e.bottles, drums, storage tanks, etc.) labelled with product identity and a hazard warning (communication of the specific health hazards and physical hazards)?

• Is there a Material Safety Data Sheet readily available for each hazardous substance used?

196


• Audit & Inspection Checklists:– Hazard Communication continued:

• Is there an employee training programme for hazardous substances? Does this programme include: – An explanation of what an MSDS is and how to use and

obtain one? – MSDS contents for each hazardous substance or class of

substances? – Explanation of "Right to Know?" – Identification of where an employee can see the employers

written hazard communication program and where hazardous substances are present in their work areas?

– The physical and health hazards of substances in the work area, and specific protective measures to be used?

– Details of the hazard communication program, including how to use the labeling system and MSDS's?

197


• Audit & Inspection Checklists:– Hazard Communication continued:

• Are employees trained in the following: – How to recognize tasks that might result in occupational

exposure? – How to use work practice and engineering controls and

personal protective equipment and to know their limitations? – How to obtain information on the types selection, proper

use, location, removal handling, decontamination, and disposal of personal protective equipment?

– Who to contact and what to do in an emergency?

198

Section 8

Planning & Organization

199

Planning and Organization

Section 8

200

Planning and Organization• Implementation Strategies:

– There are essentially two fundamental process safety management implementation strategies:1. The focus is on systems and procedures, with less

emphasis on people. This strategy is sometimes referred to as the Short Term Approach

2. With this strategy the emphasis is on the people aspects as well as the technological methodology. This strategy is sometimes referred to as the Long Term Approach

– Organizations that wish to achieve rapid results usually adopt the first approach

201


The Implications of Management Style

202


OHSOccupational Health & Safety

EMSEnvironmentalManagement

SystemISO 14001

TPMTotal Production Maintenance

QMSQuality

ManagementSystem

ISO 9001

Quality

RCM & BOP

Environment

Health & Safety

203

Planning and Organization• Planning:

– The effectiveness of response during emergencies depends on the amount of planning and training performed.

– Management must show its support for plant safety programmes and the importance of emergency planning

– If management is not interested in employee protection and in minimizing property loss, little can be done to promote a safe workplace.

– It is therefore management's responsibility to see that a programme is instituted and that it is frequently reviewed and updated.

204

Planning and Organization• Planning contd.:

– The input and support of all employees must be obtained to ensure an effective programme.

– The emergency response plan should be developed locally and should be comprehensive enough to deal with all types of emergencies specific to that site.

– When emergency action plans are required by a particular standard the plan must be in writing. The general exception is for organizations with ten or fewer employees when the plan may be communicated orally to employees.

205


• The Four Phases of Comprehensive Emergency Planning and Organization:1. Mitigation

2. Preparedness

3. Response

4. Recovery

206


• The Phases of Comprehensive Emergency Planning and Organization:1. Mitigation:

• Any activities which actually eliminate or reduce the occurrence of a disaster. Mitigation also includes long-term activities which reduce the effects of unavoidable disasters.

2. Preparedness:• Preparedness activities are necessary to the extent that

mitigation measures have not, or cannot, prevent disasters. In the preparedness phase, governments, organizations, and individuals develop plans to save lives and minimize disaster damage. Preparedness measures also seek to enhance disaster response operations.

207


• The Phases of Comprehensive Emergency Planning and Organization:3. Response:

• Response activities follow an emergency of disaster. Generally, they are designed to provide emergency assistance for casualties. They also seek to reduce the probability of secondary damage and to speed recovery operations.

4. Recovery:• Recovery continues until all systems return to normal or

better. Short-term recovery returns vital life support systems to minimum operating standards. Long-term recovery may continue for a number of years after a disaster. Their purpose is to return life to normal, or improved levels.

208

Section 9

Emergency Response Plans

209


Section 9

210

Emergency Response Plans• The Minimum Elements of an Emergency

Response Plan:– Procedures for reporting fires and other emergencies. – Procedures for emergency evacuation, including the

type of evacuation and exit route assignments. – Procedures for employees who stay behind to

continue critical plant operations. – Procedures to account for all employees after

evacuation. – Procedures for employees performing rescue or

medical duties. – Names and/or job titles of employees to contact for

detailed plan information.

211

Emergency Response Plans• The Minimum Elements of an Emergency

Response Plan continued:– Alarm systems to alert employees and other affected

persons. – Designation and training of employees to assist in a

safe and orderly evacuation of other employees – Reviews of the emergency action plan with each

employee covered when the following occur:• The plan is developed or an employee is initially assigned to

a job• An employee’s responsibilities under the plan changes• The plan is changed.

212

Emergency Response Plans• The Emergency Response Plan should address

all potential emergencies that can be expected in the workplace:– It is essential to perform a hazard audit to determine

toxic materials in the workplace, hazards, and potentially dangerous conditions.

– For information on chemicals, the manufacturer or supplier can be contacted to obtain Material Safety Data Sheets. These forms describe the hazards that a chemical may present, list precautions to take when handling, storing, or using the substance, and outline emergency and first-aid procedures.

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• The employer must list in detail the procedures to be taken by those employees who must remain behind to care for essential plant operations until their evacuation becomes absolutely necessary. Duties of employees who remain behind may include:– Monitoring plant power supplies water supplies, and other

essential services that cannot be shut down for every emergency alarm

– Use of fire extinguishers– Communicating updated information on the state of the

emergency to the energency control centre.

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• For emergency evacuation:– Use of floor plans or workplace maps that clearly show the

emergency escape routes and safe or refuge areas should be included in the plan.

– All employees must be told what actions they are to take in emergency situations that may occur in the workplace, such as a designated meeting location after evacuation.

– The emergency evacuation plan must be reviewed with employees initially when the plan is developed, whenever the employees' responsibilities under the plan change, and whenever the plan is changed.

– Trained marshals must be appointed to assist in the evacuation of employees and to conduct roll calls

– A copy of the emergency evacuation plan should be kept where employees can refer to it at convenient times.

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• Chain of Command:– A chain of command should be established to minimize

confusion so that employees will have no doubt about who has authority for making decisions.

– Responsible individuals should be selected to coordinate the work of the emergency response team.

– In larger organizations there should be a plant coordinator in charge of plant-wide operations, public relations, and ensuring that outside aid is called in.

– Because of the importance of these functions, adequate backup must be arranged so that trained personnel are always available.

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• The Duties of the Emergency Response Team Coordinator should include the following: – Assessing the situation and determining whether an

emergency exists that requires activating the emergency procedures

– Directing all efforts in the area including evacuating personnel

– Ensuring that outside emergency services such as medical aid and local fire departments are called in when necessary

– Directing the shutdown of plant operations when necessary

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• Communications:– During a major emergency involving a fire or explosion it may

be necessary to evacuate offices in addition to manufacturing areas

– Normal services, such as electricity, water, and telephones, may be nonexistent

– Under such conditions, it may be necessary to have an alternate area to which employees can report or that can act as a focal point for incoming and outgoing calls

– Provision should be made in the plan for alternate headquarters the person designated as being in charge can be easily reached.

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• Communications:– Emergency communications equipment such as public address

systems or portable radio units should be present for notifying employees of the emergency and for contacting local authorities, such as law enforcement officials and the fire department.

– A method of communication also is needed to alert employees to the evacuation or to take other action as required in the plan. Alarms must be audible or seen by all people in the plant and have an auxiliary power supply in the event electricity is affected.

– The alarm must be distinctive and recognizable as a signal to evacuate the work area or perform actions designated under the emergency action plan.

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• Communications:– The employer must explain to each employee the means for

reporting emergencies, such as manual pull box alarms, public address systems, or telephones.

– Emergency phone numbers should be posted on or near telephones, on employees' notice boards, or in other conspicuous locations.

– The warning plan should be in writing and management must be sure each employee knows what it means and what action is to be taken.

– It may be necessary to notify other key personnel such as the plant manager or physician during off-duty hours. An updated written list of key personnel should be kept listed in order of priority.

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• Accounting for Personnel:– Management will need to know when all personnel have been

accounted for. This can be difficult during shift changes or if contractors are on site.

– A responsible person in the control center must be appointed to account for personnel and to inform police or Emergency Response Team members of those persons believed missing.

• Security– During an emergency, it is often necessary to secure the area to

prevent unauthorized access and to protect vital records and equipment.

– Certain records also may need to be protected. These records may be stored in duplicate outside the plant or in protected secure locations within the plant.

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Emergency Response Plans• Emergency Response Teams:

– Emergency Response Teams are the first line of defense in emergencies.

– Before assigning personnel to these teams, the employer must assure that employees are physically capable of performing the duties that may be assigned to them.

– Depending on the size of the plant there may be one or several teams trained in the following areas: • Use of various types of fire extinguishers • First aid, including cardiopulmonary resuscitation (CPR)• Shutdown procedures • Evacuation procedures • Chemical spill control procedures • Use of self-contained breathing apparatus (SCBA)• Search and emergency rescue procedures • Incipient and advanced stage firefighting.

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Emergency Response Plans• Training:

– Training is important to the effectiveness of an emergency plan.

– Emergency Response Teams:• Should be trained in the types of possible emergencies and

the emergency actions to be performed. • Must be informed about special hazards, such as storage

and use of flammable materials, toxic chemicals, radioactive sources, and water-reactive substances, to which they may be exposed during fire and other emergencies and receive the necessary specialist training.

• Must be ttained to determine when not to intervene,forexample team members must be able to determine if the fire is too large for them to handle or whether search and emergency rescue procedures should be performed.

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– Training for each type of disaster response is necessary so thatemployees know what actions are required.

– In addition to the specialized training for Emergency Response Team members, all employees should be trained in the following: • Evacuation plans• Alarm systems • Reporting procedures for personnel • Shutdown procedures • Types of potential emergencies

– These training programs must be provided as follows:• Initially when the plan is developed • For all new employees • When new equipment, materials, or processes are introduced • When procedures have been updated or revised • When drills show that employee performance must be improved • At least annually.

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– The emergency control procedures should be written in concise terms and be made available to all personnel.

– An emergency drill should be held for all personnel, at random intervals at least annually, and an evaluation of performance made immediately by management and employees.

– When possible, drills should include groups supplying outside services such as fire and ambulance departments.

– Emergency plans should be coordinated with other companies potentailly affeceted by an emergency.

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Emergency Response Plans• Personal Protection:

– Effective personal protection is essential for any person who may be exposed to potentially hazardous substances or situations during an emergency.

– In emergency situations employees may be exposed to a wide variety of hazardous circumstances, including: • Chemical splashes or contact with toxic materials • Falling objects and flying particles • Unknown atmospheres that may contain toxic gases, vapors

or mists, or inadequate oxygen to sustain life • Fires and electrical hazards

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– It is extremely important that employees be adequately protected in emergency situations

– Some of the safety equipment that may be used inaan emergency situation includes: • Safety glasses, goggles, or face shields for eye protection • Hard hats and safety shoes for head and foot protection • Proper respirators for breathing protection • Whole body coverings chemical suits, gloves, hoods, and

boots for body protection from chemicals • Body protection for abnormal environmental conditions such

as extreme temperatures.

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– Respirators: • Professional consultation will most likely be needed in providing

adequate respiratory protection. • Respiratory protection is necessary for toxic atmospheres of dust,

mists, gases, or vapors and for oxygen-deficient atmospheres.• There are four basic categories of respirators:

1. Air-purifying devices (filters, gas masks, and chemical cartridges),which remove contaminants from the air but cannot be used in oxygen-deficient atmospheres.

2. Air-supplied respirators (hose masks, air line respirators), which should not be used in atmospheres that are immediately dangerous to life or health.

3. Positive-pressure self-contained breathing apparatus (SCBA), which are required for unknown atmospheres, oxygen-deficient atmospheres, or atmospheres immediately dangerous to life or health.

4. Escape masks.

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– Respirators: • A positive-pressure self-contained breathing apparatus

(SCBA) offers the best protection to employees involved in controlling emergency situations.

• Conditions that require a positive-pressure SCBA include the following:1. Leaking cylinders or containers, smoke from chemical fires, or

chemical spills that indicate high potential for exposure to toxic substances.

2. Atmospheres with unknown contaminants or unknown contaminant concentrations, confined spaces that may contain toxic substances or oxygen-deficient atmospheres.

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– Confined Spaces: • Emergency situations may involve entering confined spaces

to rescue employees who are overcome by toxic compounds or who lack oxygen.

• Permit required confined spaces include tanks, vaults, pits, sewers and pipelines.

• Entry into permit required confined spaces can expose the employee to a variety of hazards, including toxic gases, explosive atmospheres, oxygen deficiency, electrical hazards, and hazards created by mixers and impellers that have not been deactivated and locked out.

• Even in an emergency personnel must never enter a permit required confined space unless the atmosphere has been tested for adequate oxygen, combustibility, and toxic substances.

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– Confined Spaces: • Conditions in a permit-required confined space must be considered

immediately dangerous to life and health unless shown otherwise.• If a permit-required confined space must be entered in an emergency the

following precautions must be adhered to:– All lines containing inert, toxic, flammable, or corrosive materials must be

disconnected or blocked off before entry.– All impellers, agitators, or other moving equipment inside the vessel must be

locked out.– Appropriate personal protective equipment must be worn by employees before

entering the vessel. Mandatory use of harnesses must be stressed.– Rescue procedures must be specifically designed for each entry. A trained

standby person must be present. This person should be assigned an SCBA and must maintain unobstructed lifelines and communications to all workers within the permit-required confined space and be prepared to summon rescue personnel if necessary. The stand-by person should not enter the confined space until adequate assistance is present.

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Emergency Response Plans• Medical Assistance:

– In a major emergency time is critical factor in minimizing injuries.

– The minimum requirement is to have the following medical and first-aid services: • The employer must ensure that a person or persons are

adequately trained to render first aid. The first aid is to begin within 3 to 4 minutes of the incident if the injury is of a serious nature.

• Where the eyes or body of any employee may be exposed to injurious corrosive materials, eye washes or suitable equipment for quick drenching or flushing must be provided in the work area for immediate emergency use. Employees must be trained to use the equipment.

• The employer must ensure the ready availability of medical personnel for advice and consultation on matters of employees' health. This does not mean that health care must be provided, but rather that, if health problems develop in the workplace, medical help will be available to resolve them.

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Emergency Response Plans• Medical Emergency Plans:

– In preparation for an emergency:• Survey the medical facilities near the place of business and make

arrangements to handle routine and emergency cases. A written emergency medical procedure should then be prepared for handling accidents with minimum confusion.

• If the organization is located far from medical facilities, at least one and preferably more employees on each shift must be adequately trained to render first aid.

• First-aid supplies should be provided for emergency use. This equipment should be ordered through consultation with a medical doctor.

• Emergency phone numbers should be posted in conspicuous places near or on telephones.

• Sufficient ambulance service should be available to handle any emergency. This requires advance contact with ambulance services to ensure they become familiar with plant location, access routes and hospital locations.

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Emergency Response Plans• Dealing with Spillage:

– The effects of potentially disastrous spillage incidents to health and the environment can be substantially reduced by systematically prepared and tested procedures and plans.

– There sound reasons for preparing emergency spillage response plans, which include the following:• It reduces the thinking time required after a spillage incident has

occurred• It helps to make systematic, orderly and effective what would

otherwise be chaotic and ineffective• It is good business management and forms an integral part of the

Organisation’s Environmental Management System• It helps to contain the spillage incident, to minimise potential

effects on people and the extent of the damages to resources andthe environment.

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– Discharges of Spillages Down Drains:• Following a spillage of a chemical / hazardous aqueous liquid, it is

tempting to wash it with water hoses into the drainage system leading to the sewers or stormwater drains.

• In some cases, where the material spilt is relatively non-toxic and water-soluble this may be appropriate. However, great care should be used in adopting this procedure as statutory requirements caneasily be infringed.

• Legal responsibility for the safe containment and disposal of any chemical spillage lies with the producer of the waste.

• If a spill should occur immediate action should be taken to contain the chemical, by the use of spill kits, absorbent materials such as sand, earth or vermiculite, and the use of proprietary booms, toprevent it from entering any drain or watercourse.

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– Discharges of Spillages Down Drains:• If an unplanned discharge of hazardous substances occurs,

the local autority should be informed as soon as possible, to enable them to protect sewerage workers and minimise the effect of the spillage on the treatment works. This is particularly important when the drain is a surface water drain, which discharges directly to a water course.

• It is good practice to differentiate the drainage systems on sites by marking the manhole covers.

• If a spill should occur, immediate action should be taken to contain the spillage, to prevent it from entering any drains or watercourses.

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– Emergency Materials and Equipment:• Sand and earth:

– These are versatile containment materials which may be used to soak up spillages of oil and chemicals and used in sand bags to block off drains or to direct flows to a predetermined collection point.

– Sand should be kept dry and a shovel should be available. – Contaminated material must be properly disposed of and must

not be washed into the drainage system.• Proprietary absorbents:

– These serve a similar purpose to sand. They are available as granules, sheets, pillows or a loose powder.

– Although most absorbents are designed for hydrocarbon spills, products are available for chemical spills.

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– Emergency Materials and Equipment:• Sealing devices and substances for damaged containers:

– These devices and materials are designed for use when a tank, storage drum, valve or pipe has been punctured or damaged.

– Leak sealing devices may take the form of a pad or clamp which is put over the damaged area like a plaster, or they may be pre-shaped, inserted into the damaged area and then inflated.

– Leak sealing putties are also available.• Drain seals:

– There are several different types of drain seal, including those which can be used to seal a drainage grid by covering or blocking the drain, and those which fit in a pipe.

– The use of a pipe seal may enable the drains to be used as a retention system, which may provide a significant volume of containment.

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– Emergency Materials and Equipment:• Booms:

– Booms designed for use on watercourses may also be used to isolate drains or divert or contain spillages.

– There are two types of booms:» Absorbent booms are filled with absorbent material which can be

suitable for hydrocarbons, aqueous chemicals or both.» Plastic physical barrier booms can be inflated with air or water.

• Personal Protective Equipment:– In addition specialised spillage contrl equipment suitable PPE such as

gloves, gauntlets, goggles, visors, wellington boots, etc. should also be provided in a convenient location, to protect individuals involved in dealing with spillage incidents.

– Specific incidents may require specialist PPE, such as Respiratory Protective Equipment - RPE, to protect individuals involved in dealing with spillage incidents.

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Emergency Response Plans• Fire Prevention Plans:

– A fire prevention plan should be written, kept in the workplace, and available for employee review.

– Minimum provisions of a fire prevention plan include:• A list of all major fire hazards, proper handling and storage

procedures for hazardous materials, potential ignition sources and their control, and the type of fire protection equipment necessary to control each major hazard.

• Procedures to control accumulations of flammable and combustible waste materials.

• Procedures for regular maintenance of safeguards installed on heat-producing equipment to prevent the accidental ignition of combustible materials.

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Emergency Response Plans• Fire Prevention Plans:

– Minimum provisions of a fire prevention plan contd:• Name or job title of employees responsible for maintaining

equipment to prevent or control sources of ignition or fires.• Name or job title of employees responsible for the control of

fuel source hazards.• In addition, when employees are assigned to a job, they

must be informed of any fire hazards that they may be exposed to.

• The emploeyer must also review with each employee those parts of the fire prevention plan that are necessary for self-protection.

Section 10

Safe Operations

241

Safe Operations

Section 10

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Safe Operations• Excavation, Trenching and Shoring:

– Excavation and trenching are among the most hazardous construction operations.

– The Fatality rate for trenching is twice the level for general construction.

– What is the difference between an excavation and a trench?• OSHA defines an excavation as any man-made cut, cavity, trench,

ordepression in the earth’s surface formed by earth removal. This can include excavations for anything from cellars to highways.

• A trench is defined as a narrow underground excavation that is deeper than it is wide, and no wider than 15 feet (4.5 meters).

– What are the dangers of trenching and excavation operations?• Cave-ins pose the greatest risk and are much more likely than

other excavation-related accidents to result in worker fatalities.• Other potential hazards include falls, falling loads, hazardous

atmospheres, and incidents involving mobile equipment.

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– Dynamic Site Conditions:• Cave ins result from:

– Vibrations– Adjacent Structures– Freezing and Thawing– The Weight of the Soil Itself– Addition or Removal of Water– Reduction in Frictional and Cohesive Capacities of Soil

– How do most deaths Occur:– Instantaneously– In trenches up to 5 m deep– With absolutely no warning– In seemingly safe conditions– With workers in a bent or lying position

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Safe Operations• Excavation ,Trenching and Shoring:

– Site Evaluations:• Before beginning excavations:

– The site must be assessed– Potential hazards must be determined– Known hazards reduced or eliminated– Emergency procedures established– Periodic inspection intervals determined– Utility locations must be staked or marked

– Basic Safety Requirements:– Conduct inspections before each work shift– Do not work over unprotected employees– Wear proper personal protective equipment– Provide walkways or bridges over trenches– Provide trench exits within 25 ft (7.62 m) of workers in trenches more

than 4 ft (1.22 m) deep– Ensure spoilage is at least 2 ft (0.61 m) from trench edges

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– Foot and Vehicle Traffic Accident Prevention:• Warn and reroute public traffic• Post signs, barricades and flagmen• Mandate use of reflective vests• Warn site traffic • Install protective supports systems

– Surface Encumbrances:• Removed• Relocated• Supported to protect site personnel• Examples include

– Fencing– Posts– Telephones– Cable– Electrical Access Boxes

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– Underground Installations:• Utility lines must be located before excavating begins• Utility companies or owners must be contacted:

– Response times must be considered– Advised of the proposed work– Questions concerning underground installations need to be

answered and drawings reviewed– Underground installations must be determined by safe and

acceptable means– Excavated underground installations must be protected.

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– Access and Egress:• Structural Ramps:• To be used only by people• Must be designed by a “Competent Person”• Egress required every 25 ft (7.62 m).

– Trenches more than 5 ft (1.52 m) deep:• Require shoring• Or must have a stabilized slope• In hazardous soil conditions trenches less than 5 ft (1.52 m)

deep require shoring.

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– Hazardous Atmospheres:• Testing and Controls:

– Oxygen deficiency– Flammable atmospheres

• Emergency Rescue Equipment:– Availability– Lifelines

– Hazards and Water Accumulation:• Adequate precautions must be taken when working in accumulated

water• Controlling water and water removal must be monitored by a

“Competent Person”• Ditches, dikes or comparable means should be used to prevent

surface water from entering excavations.

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– Stability of Adjacent Structures:• When stability is endangered support systems must be

used.• Excavation below the base of foundation will not be

permitted when it poses a hazard except when:– A support system is provided– The excavation is in stable rock– A registered professional has approved the site or deemed the

situation will not pose a hazard.– Site Inspections:

• Daily inspections must be made by a ‘Competent Person”of:– Excavations– Adjacent Areas– Protective Systems

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– Fall Protection:• Guardrails must be provided for crossing over excavations• Barriers must be provided for remotely located excavations.

– General Requirements for Protective Systems:• Each employee must be protected from cave-ins by an

adequately designed system. Exceptions are:– Excavations made in stable rock– Excavations less than 5 ft (1.52 m)

• Protective systems must have the capacity to resist all loads that are expected to be applied to the system

• The design of benching, sloping and shoring systems musty comply with the relevant design codes and legislation.

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Safe Operations• Mechanical Lifting Systems:

– General Requirements:• The employer shall comply with the manufacturer's

specifications and limitations applicable to the operation of any and all cranes, derricks, hoists etc.

• Attachments used with cranes shall not exceed the capacity, rating, or scope recommended by the manufacturer.

• Rated load capacities, and recommended operating speeds, special hazard warnings or instructions shall be conspicuously posted on all equipment.

• Instructions or warnings shall be visible to operators while they are at their control stations.

• Hand signals to operators shall be those prescribed by the applicable standards.

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– General Requirements:• The employer shall designate a competent person who shall

inspect all machinery and equipment prior to each use, and during use, to make sure it is in safe operating condition. Any deficiencies shall be repaired, or defective parts replaced, before continueduse.

• A thorough annual inspection of the hoisting machinery shall be made by a competent person

• The employer shall maintain a record of the dates and results ofinspections for each hoisting machine and piece of equipment.

• Belts, gears, shafts, pulleys, sprockets, spindles, drums, fly wheels, chains, or other reciprocating, rotating, or other moving parts or equipment shall be guarded if such parts are exposed tocontact by employees, or otherwise create a hazard.

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– General Requirements:• All exhaust pipes shall be guarded or insulated in areas where

contact by employees is possible in the performance of normal duties.

• Whenever internal combustion engine powered equipment exhausts in enclosed spaces, tests shall be made and recorded tosee that employees are not exposed to unsafe concentrations of toxic gases or oxygen deficient atmospheres.

• All windows in cabs shall be of safety glass that introduces no visible distortion that will interfere with the safe operation of the machine.

• Where necessary for rigging or service requirements, a ladder, or steps, shall be provided to give access to a cab roof.

• Guardrails, handholds, and steps shall be provided on cranes foreasy access to the car and cab, conforming to applicable standards

• Platforms and walkways shall have anti-skid surfaces.

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– General Requirements:• Fuel tank filler pipe shall be located in such a position, or protected

in such manner, as to not allow spill or overflow to run onto the engine, exhaust, or electrical equipment of any machine being fueled.

• An accessible fire extinguisher shall be available at all operator stations or cabs of equipment.

• Except where electrical distribution and transmission lines havebeen de-energized and visibly grounded at point of work or where insulating barriers have been erected to prevent physical contact with the lines, equipment or machines shall not be operated in proximity to power lines.

• No modifications or additions which affect the capacity or safe operation of the equipment shall be made by the employer withoutthe manufacturer's written approval. If such modifications or changes are made, the capacity, operation, and maintenance instruction plates, tags, or decals, shall be changed accordingly.

• In no case shall the original safety factor of the equipment be reduced.

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– Basic Sling Operating Practices:• Slings that are damaged or defective must not be used• Slings must not be shortened with knots or any makeshift devices• Slings should not be kinked or twisted• Slings must not be loaded in excess of their rated capacity• Slings must be securely attached to the load• Slings must be padded to protect them from the sharp edges of

their loads• Suspended loads must be kept free of obstructions• All employees must be kept clear of loads about to be lifted and of

suspended loads• Hands or fingers must not be placed between the sling and it’s

load whilst the sling is being tightened around the load• Shock loading is prohibited• A sling must not be pulled from under a load when the load is

resting on the sling• Slings such be inspected each time before use• Slings shall inspected annually by a “Competent Person”.

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– The most frequent causes of forklift accidents:• Inattention• Distraction• Excessive Speed • Poor Driving Habits• Lack of Training

– How most forklift injuries occur:• Overloading causing the forklift to turn over• Moving or turning the forklift with the forks raised and/or

extended• Load instability causing turnover• Obstructions in the path of travel or lift • Using a forklift outside of design limitations• Striking a pedestrian.

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– Forklift driver training requirements:• Classroom training covering safety rules• Material handling techniques• Operating techniques • Driver’s performance test.

– Forklift driver retraining requirements :• When there are Changes in vehicle and handling equipment• After a close call incident• After a failure to follow safety procedures• If there is reason to doubt a driver’s proficiency.

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– The main elements of the forklift safety programme• Written safe work procedures:

– Company forklift procedures reviewed annually– Daily operator inspections documented– Driving training and proficiency tests documented.

• Employee training• Driving proficiency• Effective forklift maintenance.

– Forklift operating areas:• Aisles must be well lit and free of obstructions• Aisles must be clearly demarcated and be of sufficient width• Driving surfaces must be even and well maintained• Pedestrian movement must be accounted for• Regulatory signs must be displayed and enforced• Guardrails, door warnings, mirrors and other standard precautions

must be considered and installed.

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Safe Operations• Hot Work Permits:

– A permit must be issued for hot work operations conducted on or near a covered process

– The permit must document:• That the fire prevention and protection requirements have

been implemented prior to beginning the hot work operations

• The date(s) authorized for hot work • Identify the object on which hot work is to be performed.

– The permit must be kept on file.

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Safe Operations• Management of Change:

– Contemplated changes to a process must be thoroughly evaluated to fully assess their impact on employee safety and health and to determine needed changes to operating procedures

– Written procedures to manage changes to processes chemicals, technology and equipment and procedures must be established and implemented

– These written procedures must ensure that the following considerations are addressed prior to any change: • The technical basis for the proposed change, • Impact of the change on employee safety and health, • Modifications to operating procedures, • Necessary time period for the change, and • Authorization requirements for the proposed change• Training on the changes.

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Safe Operations• Incident Investigation :

– A crucial part of the process safety management programme is a thorough investigation of incidents to identify the chain of events and causes so that corrective measures can be developed and implemented.

– An incident investigation must be initiated as promptly as possible, but not later than 48 hours following the incident

– An investigation report must be prepared including at least: • Date of incident, • Date investigation began, • Description of the incident, • Factors that contributed to the incident• Recommendations resulting from the investigation.

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Section 11

Hazardous Chemicals

263

Hazardous Chemicals

Section 11

264

Hazardous Chemicals• When hazardous chemicals are used in the

workplace employers must:– Develop and maintain written safety information

identifying workplace chemical and process hazards, equipment used in the processes, and technology used in the processes

– Perform a workplace hazard assessment including:• Identification of potential sources of accidental releases• Identification of any previous release within the facility that

had a potential for catastrophic consequences in the workplace

• Estimation of workplace effects of a range of releases, and estimation of the health and safety effects of such a range on employees.

265

Hazardous Chemicals– Perform a workplace hazard assessment including:

• Consulting with employees and their representatives on the conducting of hazard assessments and the development of chemical accident prevention plans and provide access to these and other required records

• Establish a system to respond to the workplace hazard assessment findings which addresses prevention, mitigation and emergency responses

• Review periodically the workplace hazard assessment and response system

• Develop and implement written operating procedures for the chemical processes, including procedures for each operating phase, operating limitations and safety and health considerations

• Provide written safety and operating information for employees and employee training in operating procedures.

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Hazardous Chemicals– Perform a workplace hazard assessment including:

• Ensure contractors and contract employees are provided with appropriate information and training

• Train and educate employees and contractors in emergency response procedures

• Establish a quality assurance program to ensure that initial process related equipment, maintenance materials, and spare parts are fabricated and installed consistent with design specifications

• Establish maintenance systems for critical process related equipment, including written procedures, employee training, appropriate inspections and testing of such equipment to ensure ongoing mechanical integrity

• Conduct pre-startup safety reviews of all newly installed or modified equipment

• Establish and implement written procedures managing change to process chemicals, technology, equipment and facilities

• Investigate every incident that results in or could have resulted in a major accident in the workplace

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Hazardous Chemicals– Process safety information must include information on the

hazards of the hazardous chemicals used or produced by the process, information on the technology of the process, and information on the equipment in the process.

– Information on the hazards of the hazardous chemicals in the process must consist of at least the following :• Toxicity• Permissible exposure limits, • Physical data, • Reactivity data, • Corrosivity data• Thermal and chemical stability data • Hazardous effects of inadvertent mixing of different materials.

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Hazardous Chemicals– Information on the technology of the process must include at least the

following:• A block flow diagram or simplified process flow diagram,• Process chemistry,• Maximum intended inventory,• Safe upper and lower limits for such items as temperatures, pressures,

flows etc.• An evaluation of the consequences of deviations, including those affecting

the safety– Information on the equipment in the process must include the following:

• Materials of construction, • Piping and instrument diagrams (P&lDs), • Electrical classification, • Relief system design and design basis, • Ventilation system design, • Design codes and standards employed, • Safety systems (e.g., interlocks, detection or suppression systems) .

Section 12

Monitoring Equipment

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Monitoring Equipment

Section 12

270

Monitoring Equipment• Application Types:

– Workplace Monitoring: • Refers to measuring the indoor work environment, for monitoring

worker safety, for legal compliance or industrial hygiene surveys• Measure TLV’s (airborne concentrations of substances towhich

nearly all workers may be repeatedly exposed day after day without adverse health effects).

– Process Monitoring: • Refers to an application where a constant stream of gas will be

present. In most of these cases this is used to measure a changein the gas concentration, for process control, rather than personnel safety reasons.

– Stack Monitoring : • The typical applications is to monitoring stack emissions to meet

compliance with environmntal emmission regulations

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Monitoring Equipment• Direct reading instruments:

– Means that instrument provides displayinengineering units (usually ppm or percent)

– The monitoring unit is usually reading in real time– It is essential to have proper calibration:

• Without a clean zero gas and an accurate verified calibration standard—there is no point in doing any gas detection

• Gases of interest are:– Combustible – Oxygen (deficiency and enrichment)– Toxic

272

Monitoring Equipment• Catalytic sensors (Pellistors):

– Target gas is oxidized on catalytic element – The change in temperature causes a change in

resistance that is measured by the meter– The main application is combustible gases.– Their main advantage is long life – Their disadvantages are:

• Different responses for each combustible gas• Most require at least 10% oxygen to work properly• They are limited to percent-level detection• They can be poisoned.

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Monitoring Equipment• Metal Oxide Semiconductor sensors (MOS):

– These are also known as Also known as solid state, Figaro or Taguchi sensors

– The target gas reacts with MOS (SnO2 ) and changes its resistance – as measured by the meter

– Their application is nearly all oxidizable gases – Their main advantage is that they are inexpensive – Their disadvantages are:

• They are affected by humidity • They are not truly analytical—better as “go/no-go” detectors

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Monitoring Equipment• Non-Dispersive Infrared sensors (NDIR):

– The target gas absorbs infrared light at a particular wavelength

– Their application is for hundreds of compounds, especially organics

– Their main advantage is that they are extremely versatile

– Their disadvantages are:• Expensive• They be fragile and complicated to service.

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Monitoring Equipment• Photoionization Detector (PID):

– Ultraviolet light ionizes the target gas– The current produced is proportional to concentration– Their application is for Volatile Organic Compounds (VOC’s)– Their main advantages are:

• They detect a wide range of volatile organic compounds• They are quite effective when used in conjunction with

chromatographic column → Portable GC’s– Their disadvantages are:

• Nonselective among organic vapors below ionization potential of lamp

• They are affected by high humidity• UV lamps are expensive

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Monitoring Equipment• Electrochemical sensors:

– Target gas is adsorbed on an electrocatalytic sensing electrode, after passing through a diffusion medium and is electrochemically reacted

– The current produced by this reaction is directly proportional to the gas concentration.

– Their application is for Br2, CO, Cl2, ClO2, C2H4,ethylene oxide, HCHO, H2, hydrazine, HBr, HCl, HCN, H2S, NO, NO2, O3, propylene oxide, SO2 and oxygen amongst others

– Their main advantages are: • Inexpensive• Linear output• Can be miniaturized

– Their disadvantages are:• They are prone to interferences in unskilled hands• Affected by temperature, but this is readily correctable

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Monitoring Equipment– Combustible sensors:

• Combustible gases and vapors may be ignited and propagate flame only between the limits of flammability known as the LowerExplosive Limit (LEL) and the Upper Explosive Limit (UEL)

• Mixtures of combustible gases in air below the LEL are too lean to permit propagation of flame, while mixtures above the UEL are too rich to permit combustion due to the lack of oxygen

• The LEL and the UEL are usually expressed as percentages, by volume, of combustible gas in air. These values differ from gas to gas

• The gas detection technology adopted in each case is different:– Thermal conductivity or infrared detectors are commonly used for the

detection of high concentrations (above the LEL),– Electrocatalytic detectors being very widely used for thedetection of

concentrations below the LEL.

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Monitoring Equipment– Hydrogen Sulfide Detection:

• Hydrogen sulfide (H2S) is one of the most common chemicals used or encountered by industry

• It is a flammable and highly poisonous gas • Hydrogen sulfide is also known for its corrosive effects,

particularly on sensitive electronic equipment• Hydrogen sulfide is a common hazard in a wide range of

industries, including oil and gas drilling and production, oil refining, petrochemical processing, wastewater treatment, pulp and paper production and mining

• H2S sensors are used to give an early and reliable warning that H2S is present in ambient air.

• There are two H2S detection techniques: – Electrochemical sensors – Solid state sensors.

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Monitoring Equipment– Oxygen sensors:

• Oxygen are usually of metal-air type. • They comprise an anode, an electrolyte and an air cathode• Oxygen sensors are current generators, and the current is

proportional to the rate of oxygen consumption (Faraday’s Law).

• Gases for which monitoring equipment is available include Br2, CO, Cl2, ClO2, C2H4, ethylene oxide, HCHO, H2, hydrazine, HBr, HCl, HCN, H2S, NO, NO2, O3, propylene oxide, and SO2.

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Section 13

Appendices - Case Studies, Examples

and Forms

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Case Studies

Section 13

282

Appendices

1. Example of Hazard Communication Programme

2. Example of an MSDS

3. Process Safety Management (OSHA Standard)

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ACME TECHNOLOGIES HAZARD COMMUNICATION PROGRAM I. General Company Policy The purpose of this document is to comply with the North Carolina Occupational Safety and Health Hazard Communication Standard, 13 NCAC 7C.0101(a)(105), by compiling a hazardous chemicals list, by using material safety data sheets (MSDSs), by ensuring containers are labeled, and by providing employees with training. This program applies to all operations in the company where employees may be exposed to hazardous substances under normal working conditions or during an emergency situation. The safety and health manager is the program coordinator, acting as the representative of the President who has overall responsibility for the program. The safety and health manager will review and update the program, as necessary. Copies of this written program may be obtained from the office of the health and safety manager. . Under this program, employees will be informed of the contents of the Hazard Communication Standard, the hazardous properties of chemicals with which they work, safe handling procedures, and measures to take to protect themselves from these chemicals. They will also be informed of the hazards associated with non-routine tasks, such as industrial cleaning with chemical cleansers or painting for various reasons. II. List of Hazardous Chemicals The safety and health manager will make a list of all hazardous chemicals and related work practices used in the facility, and will update the list as necessary. The list of chemicals identifies all of the chemicals used in each work process area. A separate list is available for the lab and is posted there. Each list also identifies the corresponding MSDS for each chemical. A master list of these chemicals will be maintained by, and is available from the office of the safety and health manager. III. Material Safety Data Sheets (MSDSs) MSDSs provide specific information on the chemicals employees use. The safety and health manager, will maintain a binder in his office with an MSDS on every substance on the List of Hazardous Chemicals. The MSDSs will be fully completed in accordance with the provisions found in the Hazard Communication Standard, paragraph (g). The President will ensure that each work site maintains an MSDS for hazardous materials in that area. MSDSs will be prominently displayed and readily accessible to all employees in their work areas on each work shift. The safety and health manager is responsible for acquiring and maintaining current MSDSs. He will contact the chemical manufacturer or vendor if additional information is

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necessary or if an MSDS has not been supplied with an initial shipment. All new procurements for the company must be cleared by the safety and health manager. IV. Labels and Other Forms of Warning The safety and health manager will ensure that all hazardous chemicals in the plant are properly labeled and updated, as necessary. Labels should list at least the chemical identity, manufacturer, importer, or other responsible party. The safety and health manager will refer to the corresponding MSDS to assist employees in verifying label information. Containers that are shipped from the plant will be checked by the supervisor of shipping and receiving to make sure all containers are properly labeled. If there are a number of stationary containers within a work area that have similar contents and hazards, signs will be posted on or near them to convey the hazard information. Any container that is regularly used for dispersal of a hazardous substance must be properly marked. If employees transfer chemicals from a labeled container to a portable container that is intended only for their immediate personal use, no labels are required on the portable container. Pipes or piping systems will not be labeled but their contents will be described in the training sessions. V. Non-Routine Tasks When employees are required to perform hazardous non-routine tasks such as industrial cleaning or painting, a special training session will be conducted to inform them regarding the hazardous chemicals involved and proper precautions to take to reduce or avoid exposure. VI. Training Everyone who works with, or is potentially exposed to hazardous chemicals will receive initial training in the Hazard Communication Standard and the safe use of those hazardous chemicals. A program that uses both audiovisual materials and classroom type training has been prepared for this program. Whenever a new hazard is introduced, additional training will be provided. A Safety Committee comprised of the President, the Health and Safety Manager, the Maintenance Manager, the Production Manager and two hourly production workers will hold quarterly safety meetings will also review the information presented in the initial training. The maintenance and production managers will be extensively trained regarding hazards and appropriate protective measures so they will be available to answer questions from the employee and provide daily monitoring of safe work practices. The training plan will emphasize these items:

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(1) summary of the Hazard Communication Standard and this written program;

(2) chemical and physical properties of hazardous materials and methods that can be used to detect the presence or release of chemicals;

(3) physical hazards of chemicals; health hazards, including signs and symptoms of exposure, associated with exposure to chemicals and any medical condition known to be aggravated by exposure to the chemical;

(4) procedures to protect against hazards;

(5) work procedures to follow to assure protection when cleaning hazardous chemical spills and leaks; and

(6) where MSDS are located, how to read and interpret the information on both labels and MSDSs, and how employees may obtain additional hazard information.

The safety and health manager or designee will review the training program and advise the President on training or retraining needs. Retraining is required when the hazard changes or a new hazard is introduced into the workplace , but it will be company policy to provide training monthly in safety meetings to ensure the effectiveness of the program. Three employee meetings a year will be dedicated solely to Hazard Communication. As part of the assessment of the training program, the safety and health manager will obtain input from employees regarding the training they receive and their suggestions for improving it. VII. Contractor Employers The safety and health manager upon notification by the responsible supervisor, will advise outside contractors in person of any chemical hazards that may be encountered in the normal course of their work on the premises, the labeling system in use, the protective measures to be taken, and the safe handling procedures to be used. In addition, the safety and health manager will notify these individuals of the location and availability of MSDSs. Each contractor bringing chemicals on-site must provide Acme Technologies with the appropriate hazard information of these substances, including the labels used and the precautionary measures to be taken in working with these chemicals. VIII. Additional Information All employees, or their designated representative, can obtain further information on this written program, the Hazard Communication Standard, applicable MSDSs, and the List of Hazardous Chemicals at the office of the safety and health manager.

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APPENDIX A Compliance Checklist

ITEM INITIALS

DATE

Listed all hazardous chemicals in our workplace

Established a file for information on hazardous chemicals

Obtained an MSDS for each hazardous chemical in use

Developed a system to ensure that all incoming hazardous chemicals are labeled

Reviewed each MSDS to be sure it is complete

Made sure MSDSs are available where necessary

Developed a method to communicate hazards to employees and others

Informed a method to communicate hazards to employees and others

Alerted employees to other forms of warnings that may be used

Designated person(s) responsible for:

Coordinating HAZCOM program:

Hazardous chemicals list:

Labels:

MSDSs:

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Training:

APPENDIX B LIST OF HAZARDOUS CHEMICALS AT ACME TECHNOLOGIES AS OF JUNE 5, 1994 Oil Mobil Vactra No. 2 ISO VG 68 (Way Lube) Oil Mobil DTE Heavy ISO VG 100 (Lube Oil) Oil Mobil DTE Heavy Medium ISO VG 100 (Lube Oil) Oil Mobil Velocite No. 10 (Spindle Oil) Cutting Oil Monroe Prime Cut Water Soluble Hydraulic Oil Sunoco Sunvis 732 Simple Green Concentrated Industrial Cleaner Monroe Cool Tool II Cutting and Tapping Fluid Kool Mist Coolant for Mist Coolant System Starrett Granite Surface Plate Cleaner WD-40 Aerosol Cans Loctite Pneumatic Hydraulic Sealant 545 Item No. 54531 Loctite Threadlocker 242 Item No. 24231 Loctite Threadlocker 262 Item No. 26231 Loctite PST Pipe Secant 567 Item No. 56747 Permatex Parr Hand Cleaner Part No. 65-108 Clover Lapping Compound Grade A & E Main Production Electrolyte SC-44 Neutralyte Cab - O - Sil (fumed silica) Oil Immersion Cleaner Spray paint Stoddard Solvent Propane Fuel Acetic Acid LAB: Hydranal Composite 2 Mineral Spirits 66 111 Trichloroethane Ammonium Hydroxide

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WD-40 Hydranal Titant 2NH

SAFETY DATA SHEET according to EC directive 2001/58/EC

Monomethylformamide Version 2.1 Revision Date 07.10.2005 Ref. 130000000313

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This SDS adheres to the standards and regulatory requirements of the European Community and may not meet the regulatory requirements of other countries.

1. IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY/UNDERTAKING

Product information

Product name : Monomethylformamide Synonyms : NMF Use of the Substance/Preparation

: solvent

Company : Du Pont de Nemours (Belgium) BVBA

DuPont Chemical Solutions Enterprise Ketenislaan 1, Haven 1548 B-9130 Kallo Belgium

Telephone : +32-3-730.2211

Telefax : +32-3-730.2390

Emergency telephone number

: +44-(0)8456-006.640

2. COMPOSITION/INFORMATION ON INGREDIENTS

Chemical name of the substance

: N-Methylformamide

Chemical Name CAS-No. EC-No. Classification Concentration [%]

N-Methylformamide 123-39-7 204-624-6 Repr.Cat.2; R61 Xn; R21

99,5

Carbon monoxide 630-08-0 211-128-3 F+; R12 Repr.Cat.1; R61 T; R23 -R48/23

< 0,1

For the full text of the R phrases mentioned in this Section, see Section 16. 3. HAZARDS IDENTIFICATION

May cause harm to the unborn child. Also harmful in contact with skin.

4. FIRST AID MEASURES

General advice

: Never give anything by mouth to an unconscious person.

Inhalation

: Move to fresh air. Oxygen or artificial respiration if needed. Call a physician immediately.



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Skin contact

: Wash off immediately with plenty of water for at least 15 minutes. Take off contaminated clothing and shoes immediately.

Eye contact

: Rinse thoroughly with plenty of water for at least 15 minutes and consult a physician. Keep eye wide open while rinsing. Remove contact lenses.

Ingestion

: Rinse mouth. Immediately give plenty of water (if possible charcoal slurry). Do not induce vomiting. Consult a physician if necessary.

5. FIRE-FIGHTING MEASURES

Suitable extinguishing media

: water, dry powder, foam, carbon dioxide (CO2),

Specific hazards during fire fighting

: Vapours may form explosive mixtures with air. pressure build-up Flash back possible over considerable distance.

Special protective equipment for fire-fighters

: Wear self-contained breathing apparatus and protective suit.

Further information

: Fire residues and contaminated fire extinguishing water must be disposed of in accordance with local regulations. Collect contaminated fire extinguishing water separately. This must not be discharged into drains. Cool containers / tanks with water spray.

6. ACCIDENTAL RELEASE MEASURES

Personal precautions

: Ensure adequate ventilation. Remove all sources of ignition. Wear personal protective equipment. Evacuate personnel to safe areas.

Environmental precautions

: Prevent product from entering drains. Do not contaminate surface water.

Methods for cleaning up

: Dam up. Soak up with inert absorbent material. Transfer to steel drums with a lid. Use mechanical handling equipment. After cleaning, flush away traces with water.

7. HANDLING AND STORAGE

Handling

Advice on safe handling

: Use only in area provided with appropriate exhaust ventilation. Do not breathe vapours or spray mist. Avoid contact with skin and eyes. Do not smoke.

Advice on protection against fire and explosion

: Keep away from heat and sources of ignition. Do not spray on a naked flame or any other incandescent material. Take measures to prevent the build up of electrostatic charge.

Storage

Requirements for storage areas and containers

: Containers which are opened must be carefully resealed and kept upright to prevent leakage. Keep containers tightly closed in a dry, cool and well-ventilated



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place. Store in original container.

Advice on common storage

: No materials to be especially mentioned.

Other data

: No decomposition if stored normally.

8. EXPOSURE CONTROLS / PERSONAL PROTECTION

Engineering measures

Ensure adequate ventilation. Personal protective equipment

Respiratory protection : When workers are facing concentrations above the exposure limit they must use appropriate certified respirators.

Hand protection : Material: butyl-rubber Break through time: 120 min impervious gloves

Eye protection

: tightly fitting safety goggles

Skin and body protection

: solvent-resistant apron

Hygiene measures

: General industrial hygiene practice. Wash hands before breaks and immediately after handling the product. Wash contaminated clothing before re-use. Discard contaminated shoes.

9. PHYSICAL AND CHEMICAL PROPERTIES

Form

: liquid,

Colour

: colourless,

Odour

: amine-like,

Solidification point : -4 °C

Boiling point/range : 198 - 199 °C at 1 013 hPa

Flash point

: 119 °C

Ignition temperature

: 323 °C

Lower explosion limit

: 1,8 %(V)

Upper explosion limit

: 19,7 %(V)

Vapour pressure

: 0,267 hPa at 25 °C

Relative density

: 1,00 at 25 °C



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Water solubility

: , completely miscible

10. STABILITY AND REACTIVITY

Conditions to avoid

: Decomposes on heating.

Hazardous decomposition products

: Carbon monoxide

Hazardous reactions

: No decomposition if stored and applied as directed.

11. TOXICOLOGICAL INFORMATION

Acute oral toxicity • N-Methylformamide : LD50/ rabbit : 4 000 mg/kg Acute inhalation toxicity • N-Methylformamide : ALC/ rat : > 10 mg/l

Acute dermal toxicity • N-Methylformamide : ALD/ rabbit females: 1 500 mg/kg

Skin irritation

: no data available

Eye irritation

: rabbit Severe eye irritation

Sensitization

: no data available

Human experience

: Excessive exposures may affect human health, as follows: Inhalation nausea, headache, dizziness, weakness

Skin contact irritation, discomfort, rash, Systemic toxicity

Eye contact severe irritation, discomfort, blurred vision

Ingestion nausea, headache, dizziness, weakness

Liver: abnormal function

Further information

: Toxic to Reproduction Category 2

12. ECOLOGICAL INFORMATION

Elimination information (persistence and degradability) Biodegradability

: no data available



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Toxicity to fish • N-Methylformamide : LC50 / 96 h/ Fathead minnow : > 5 000 mg/l

13. DISPOSAL CONSIDERATIONS

Product

: Do not dispose of waste into sewer. Can be incinerated, when in compliance with local regulations. Dispose of as special waste in compliance with local and national regulations.

Contaminated packaging

: Triple rinse containers. If recycling is not practicable, dispose of in compliance with local regulations.

14. TRANSPORT INFORMATION

Further Information : Not classified as dangerous in the meaning of transport regulations.

15. REGULATORY INFORMATION

Labelling according to EC Directives

Symbol(s) : T Toxic

Hazardous components: N-Methylformamide R-phrase(s) : R61 May cause harm to the unborn child.

R21 Also harmful in contact with skin.

S-phrase(s) : S45 In case of accident or if you feel unwell, seek medical advice

immediately (show the label where possible). S53 Avoid exposure - obtain special instructions before use. S60 This material and/or its container must be disposed of as

hazardous waste.

16. OTHER INFORMATION

Text of R phrases mentioned in Section 2

R12 Extremely flammable. R21 Harmful in contact with skin. R23 Toxic by inhalation. R48/23 Toxic: danger of serious damage to health by prolonged exposure through inhalation. R61 May cause harm to the unborn child.



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The information provided in this Safety Data Sheet is correct to the best of our knowledge, information and belief at the date of its publication. The information given is designed only as a guidance for safe handling, use, processing, storage, transportation, disposal and release and is not to be considered a warranty or quality specification. The information relates only to the specific material designated and may not be valid for such material used in combination with any other materials or in any process, unless specified in the text.

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