pdc maharshi mehta occucon

Hazard and Risk Assessment Hazard and Risk Assessment

PDC on Hazard and Risk AssessmentPDC on Hazard and Risk Assessment

Occucon 2014, Goa

February 11, 2014

Maharshi Mehta, CSP, CIHInternational Safety Systems, Inc., Washingtonville New York, USAwww.issehs.com

AgendaAgenda

Introduction to Industrial HygieneIntroduction to Industrial Hygiene HazardsHazards

– Chemical Physical and Biologcal AgentsChemical Physical and Biologcal Agents Hazards and RiskHazards and Risk Exposure LimitsExposure Limits Risk Assessment ToolsRisk Assessment Tools Case Studies Case Studies Demonstration of Risk Assessment tools Demonstration of Risk Assessment tools

©International Safety Systems, Inc. ©International Safety Systems, Inc. www.issehs.comwww.issehs.com

Industrial HygieneIndustrial Hygiene

Hazard Anticipation-Hazards likely to be present?Hazard Anticipation-Hazards likely to be present?

Hazard Recognition-What are health hazards?Hazard Recognition-What are health hazards?

Risk Evaluation-Exposed to health hazard? How much? Risk Evaluation-Exposed to health hazard? How much?

Risk Control-How can exposure be reduced?Risk Control-How can exposure be reduced?

And potential for occupational illnesses, material loss are And potential for occupational illnesses, material loss are reduced and the company liability minimizedreduced and the company liability minimized

So that.. Health risk is minimizedSo that.. Health risk is minimized

The NeedThe Need Prevent occupational illness and injury by Prevent occupational illness and injury by

reducing/eliminating health riskreducing/eliminating health risk Significant cost savings by reducing/recovering Significant cost savings by reducing/recovering

particulate/vapor emissionsparticulate/vapor emissions Regulatory requirementsRegulatory requirements Productivity increaseProductivity increase

•In the Europe, 150 million workdays are lost each year due to work In the Europe, 150 million workdays are lost each year due to work accidents and illnesses and the insurance costs 20 billion Eurosaccidents and illnesses and the insurance costs 20 billion Euros•Annual cost of occupational illnesses and injuries in Latin America is Annual cost of occupational illnesses and injuries in Latin America is about $75 billionabout $75 billion

Exposure LimitsExposure Limits Airborne concentration of a substance Repeated exposure to the substance below exposure limit

day after day is unlikely to produce adverse health effects in healthy workers

High Health Hazard Chemicals have low exposure limits. Examples of exposure limits at Huntsman

– Hydrochloric acid 5 ppm ceiling limit– Ammonia 25 ppm long term limit for 8 hours exposure

Exposure limits are Exposure limits are notnota fine line between safe and a fine line between safe and dangerous concentrations dangerous concentrations

Organizations Establishing Organizations Establishing Occupational Exposure Limits Occupational Exposure Limits (OELs)(OELs)

American Conference of Governmental Industrial American Conference of Governmental Industrial Hygienists (ACGIH), USA Hygienists (ACGIH), USA

Local Regulatory AgenciesLocal Regulatory Agencies– Occupational Safety and Health Administration (OSHA), USAOccupational Safety and Health Administration (OSHA), USA

– Health and Safety Executive (HSE), UKHealth and Safety Executive (HSE), UK

– Technical Rules for Hazardous Substances (TRGS), GermanyTechnical Rules for Hazardous Substances (TRGS), Germany

GE Established OELsGE Established OELs– More stringentMore stringent

Units of Exposure LimitsUnits of Exposure Limits

Vapor/gaseous airborne substances:Vapor/gaseous airborne substances: ppm (parts per million)- the parts of airborne ppm (parts per million)- the parts of airborne

substance per million parts of airsubstance per million parts of air ppb (parts per billion)- the parts of airborne ppb (parts per billion)- the parts of airborne

substance per billion parts of airsubstance per billion parts of air

Expressed as concentration of the airborne substance in a volume of air Expressed as concentration of the airborne substance in a volume of air

Particulate airborne substances:Particulate airborne substances: mg/mmg/m33 - - milligrams of airborne milligrams of airborne substance per cubic meter of airsubstance per cubic meter of air µg/µg/mm33 - - micrograms of airborne micrograms of airborne substance per cubic meter of airsubstance per cubic meter of air

Airborne fibers:Airborne fibers:Fibers/cc -fibers per cubic Fibers/cc -fibers per cubic centimeter of aircentimeter of air

1 m

1 m

1 m

. 1 mg

Concentration of airborne substance is 1

mg/m3

What are Hazards and RisksWhat are Hazards and Risks Hazard – Chemical, Physical and or Biological agent that

can cause harm Risk - The likelihood that the potential for harm will be

caused by hazards Hazardous substances are present most of the time Risk is dependant on (a) human exposure to hazards and

(b) degree of exposures Degree of exposure is dependant on controls provided

and work practices followed

Industrial Hygiene Risk Assessment (IHRA) is process of Industrial Hygiene Risk Assessment (IHRA) is process of determining degree of health RISK based on degree of determining degree of health RISK based on degree of HAZARDS and extent of EXPOSUREHAZARDS and extent of EXPOSURE

The NeedThe Need Assist in determining: Assist in determining:

– the need for exposure controlsthe need for exposure controls– respiratory protection and types of respiratorsrespiratory protection and types of respirators– if an illness is work related or notif an illness is work related or not

Assist in protecting company in occupational illness litigationsAssist in protecting company in occupational illness litigations Targeted medical surveillanceTargeted medical surveillance

– Medical surveillance focused on potentially exposed Medical surveillance focused on potentially exposed individualsindividuals

Methodology - PlanningMethodology - Planning

Obtain and review process information, chemical Obtain and review process information, chemical lists before handlists before hand

Obtain and review past mentoring data and Obtain and review past mentoring data and historical assessmenthistorical assessment

Review floor plan and mark areas CRA to ensure Review floor plan and mark areas CRA to ensure all areas are coveredall areas are covered

Review applicable regulation and standardsReview applicable regulation and standards Obtain list of chemicals and ingredientsObtain list of chemicals and ingredients

Where and When Should Chemical Where and When Should Chemical Risk Assesment be DoneRisk Assesment be Done Where: Where:

– Include all operations and activitiesInclude all operations and activities– Include all non-routine operations and activities such Include all non-routine operations and activities such

as, maintenanceas, maintenance– Include activities with no apparent health risk alsoInclude activities with no apparent health risk also

E.g., Warehouse; potential risk from noise and E.g., Warehouse; potential risk from noise and carbon monoxide (CO) from forklift may be presentcarbon monoxide (CO) from forklift may be present

WhenWhen– Before any new process beginsBefore any new process begins– When change in process occursWhen change in process occurs

Required for Employees, Contract Employees, Temporary Required for Employees, Contract Employees, Temporary WorkersWorkers

Chemical Risk AssessmentChemical Risk Assessment Degree of hazards

– Hydrochloric acid and ammonia Frequency and duration of handling/exposure

– How long tanker unloading is done The risk of the material becoming airborne

– % of HCl and does it become airborne Historical air monitoring results (if available) Existing engineering controls and work practices followed

– How do we collect QC sample Effectiveness of exposure control is determined or not Chemical properties: volatility, particle size, dryness

– Fly ash , coal dust Ingestion Skin contact

Site VisitSite Visit Determine frequency/duration of operation/personal Determine frequency/duration of operation/personal

exposuresexposures Determine approximate quantities of materials usedDetermine approximate quantities of materials used Observe controls - make subjective assessment of Observe controls - make subjective assessment of

effectivenesseffectiveness Interview workers and/or supervisors at each stage of Interview workers and/or supervisors at each stage of

processprocess Gather data on raw materials, finished products, by-Gather data on raw materials, finished products, by-

productsproducts Collect relevant MSDSsCollect relevant MSDSs Note specific PPE usedNote specific PPE used Start to complete Risk RankingStart to complete Risk Ranking


RankFrequency Duration

Health HazardAirborne Potential

Engineering Control

Skin Exposure

Daily Weekly monthly Yearly

Chemicals API Skin HazardExposure Potential

1 Minimal (under 30 minutes)

Any / Minimal (under 5 hours)

Any / Minimal (under 20

hours)

Any / Minimal

(under 250 hours)

OEL in range 3.1 to 10

mg/m3 or > 1000 ppm

OHC #1, OEL >1000 µg/m3 Low

Total enclosure validated by IH

monitoring

No skin hazard, temporary effects

2 About 30 min to < 2

hour5 to 15 hours

per week20 to 60 hours

per month

250 to 500 hours per

year

OEL in range 0.51 to 3

mg/m3 or 101 to 1000 ppm

OHC# 2, OEL 100 µg/m3 - 1000

µg/m3

MediumTotal enclosure NOT validated

3 About ½ Shift (2 to 4 hours)

15 to 25 hours per week

60 to 80 hours per month

Use More Frequent

Basis

OEL in range 0.01 to 0.5

mg/m3 or 10 to 100 ppm

OHC# 2, OEL 100 µg/m3 - 1000

µg/m3

High

4 About ¾ Shift (4 to 7 hours)

25 to 30 hours per week

Use More Frequent

Basis

Use More Frequent

Basis

OEL < 0.01 mg/m3 or < 10

ppm

OH Cat# 3, OEL 10 µg/m3 - 100

µg/m3

Moderate (LEV)

validated

Probable skin irritants, materials

may cause dermatitis.

Short term skin

exposure

5(over 7 hours)

Use More Frequent Basis

Use More Frequent

Basis

Use More Frequent

Basis

OH Cat# 4, OEL

1 µg/m3 - 10 µg/m3

6

Cat# 4, OEL 0.01 µg/m3 - 1 µg/m3

Moderate not

Validated

7

OH Cat# 4, OEL

< 0.01 µg/m3

Will cause skin irritation, sensitizers,

corrosives (acids, caustics, nickel).

Repeated-long Skin exposure

8

Non-fixed controls

movable LEV

9

10 No controlsMaterials toxic to

skin (ACGIH) Skin

Skin exposure certain


Final Risk Ranking Criteria

Description

Final Risk

Ranking

<50

Acceptable – process is well controlled and personal exposures are obviously unlikely to become significant – no further action required other than periodic review

1

50-200Potentially acceptable but it may be possible to further reduce exposures by adopting simple recommendations

2

200-400

Further evaluation needed – the qualitative assessment has not provided enough information to be confident that personal exposures are acceptable; air monitoring may be required.

3

> 400 Very High Risk -Implement exposure controls immediately 4

Case Study-HCl unloadingCase Study-HCl unloading

37% HCl, how hazardous the chemical is?37% HCl, how hazardous the chemical is? Ceiling Limit of 2 ppmCeiling Limit of 2 ppm Unloading is done from tankerUnloading is done from tanker Closed pipingClosed piping Unloading is done for 2 hours/weekUnloading is done for 2 hours/week Is it harmful through skin?Is it harmful through skin? Skin Contact likely?Skin Contact likely? What is final riskWhat is final risk


RankingRanking

1.1. Frequency Duration Ranking?Frequency Duration Ranking?

2.2. Hazard Ranking?Hazard Ranking?

3.3. Is it becoming easily airborne? Ranking?Is it becoming easily airborne? Ranking?

4.4. Are exposure controls provided? Effective? Are exposure controls provided? Effective? Ranking?Ranking?

Inhalation ranking multiplication of 1x2x3x4 Inhalation ranking multiplication of 1x2x3x4 rankingranking

Now what is inhalation ranking?Now what is inhalation ranking?


Skin Ranking Skin Ranking

1.1. Is HCl very harmful to skin? What is ranking?Is HCl very harmful to skin? What is ranking?

2.2. Is skin contact likely? What is ranking?Is skin contact likely? What is ranking?

Skin Exposure ranking is 1x2Skin Exposure ranking is 1x2

What is skin exposure risk?What is skin exposure risk?

Total Risk is Inhalation Ranking + Skin RankingTotal Risk is Inhalation Ranking + Skin Ranking

What is Total Ranking?What is Total Ranking?

Is risk acceptable? What needs to be doneIs risk acceptable? What needs to be done


Observations and Observations and RecommendationsRecommendations

Very important as observation based degree of risk is Very important as observation based degree of risk is more important than number based risk more important than number based risk

Provides bases for ranking used Provides bases for ranking used Obtain and enter as much of the pertinent information as Obtain and enter as much of the pertinent information as

possible based on observations and interviewspossible based on observations and interviews While making recommendations, considerWhile making recommendations, consider

– ““Quick Fix”Quick Fix”– FeasibilityFeasibility– Cost effectivenessCost effectiveness

Mention PPEs used, if anyMention PPEs used, if any

Quantitative Exposure AssessmentQuantitative Exposure Assessment

Chemical exposure monitoringChemical exposure monitoring– Direct reading instrumentsDirect reading instruments– Detector tubes (Colorimetric tubes)Detector tubes (Colorimetric tubes)– Passive monitoring with Diffusion badges/tubesPassive monitoring with Diffusion badges/tubes– Active monitoring with sampling pumpsActive monitoring with sampling pumps

Noise monitoringNoise monitoring– Area noise monitoringArea noise monitoring

– Personal noise exposure monitoring (Dosimetry)Personal noise exposure monitoring (Dosimetry) Heat stress monitoringHeat stress monitoring Ionizing radiation monitoringIonizing radiation monitoring Vibration monitoringVibration monitoring Bio-aerosol monitoringBio-aerosol monitoring

Active Air Active Air MonitoringMonitoring

Sampling pump

Sampling media

Sampling media

Active Air MonitoringActive Air Monitoring Process: Process:

– Air is drawn through a sampling media, kept in the breathing zone Air is drawn through a sampling media, kept in the breathing zone of the person potentially exposed, with a battery operated of the person potentially exposed, with a battery operated sampling pumpsampling pump

– The sampling media is analyzed and weight of contaminant The sampling media is analyzed and weight of contaminant determineddetermined

– The weight is divided by the volume of air drawn through the The weight is divided by the volume of air drawn through the media to determine contaminant concentrationmedia to determine contaminant concentration

Substance-specific accurate identification of exposureSubstance-specific accurate identification of exposure Corporate and regulatory requirementsCorporate and regulatory requirements Acceptable in litigationAcceptable in litigation Determines exposure during actual work. Not an Determines exposure during actual work. Not an

instantaneous concentration determination as in direct instantaneous concentration determination as in direct reading instrumentreading instrument

Quality Assurance in Exposure MonitoringQuality Assurance in Exposure Monitoring

Health of working people depends on exposure monitoring resultsHealth of working people depends on exposure monitoring results Ensure sampling duration is closed to the exposure duration. Ensure sampling duration is closed to the exposure duration.

– Do not miss beginning and ending of shifts as high exposure Do not miss beginning and ending of shifts as high exposure may occur during this time (e.g., cleaning of work area) may occur during this time (e.g., cleaning of work area)

– Exposure monitoring may have to begin at 6 am if shift starts at Exposure monitoring may have to begin at 6 am if shift starts at 6 am. 6 am.

Ensure calibration of sampling device before and after samplingEnsure calibration of sampling device before and after sampling Ensure sampling device is calibrated annuallyEnsure sampling device is calibrated annually Ensure sampling time is exact. Ensure sampling time does not end Ensure sampling time is exact. Ensure sampling time does not end

with 0 and 5 (e.g., 8:05 am, 8:10 am)with 0 and 5 (e.g., 8:05 am, 8:10 am)

Demonstration of Risk Demonstration of Risk Assessment Tool and DiscussionsAssessment Tool and Discussions

Control Of Substances hazardous to Health Control Of Substances hazardous to Health (COSHH) Risk Assessment Tool(COSHH) Risk Assessment Tool

Industrial Hygiene Risk Assessment Tool at one Industrial Hygiene Risk Assessment Tool at one of the largest corporationsof the largest corporations– ProcessProcess

– Computerized modelComputerized model

– Data Synthesis and analysis for 2000 + sites globallyData Synthesis and analysis for 2000 + sites globally


COSHH Assessment Tool-Part 1COSHH Assessment Tool-Part 1


COSHH Assessment Part 2COSHH Assessment Part 2


Enhanced IH ModuleEnhanced IH ModuleAssessment w/Risk Assessment integrated into IH module

Enhanced IH Module (Cont.)Enhanced IH Module (Cont.)Streamlined Add New Assessment form

Risk Assessment Details section

Enhanced IH Module (Cont.)Enhanced IH Module (Cont.)Risk Assessment Details Pending for an Existing Assessment Record

Risk Assessment Details Completed

Enhanced IH Module (Cont.)Enhanced IH Module (Cont.)Streamlined Risk Assessment Details Form with Guidance Mouseovers

Enhanced IH Module (Cont)Enhanced IH Module (Cont)

Risk Assessment Workflow Option to Submit to Reviewer

Enhanced IH Module (Cont.)Enhanced IH Module (Cont.)Risk Assessment Review Option – Special Right Required

HSE (UK) COSHH EssentialsHSE (UK) COSHH Essentials Control banding tool for small to medium size Control banding tool for small to medium size

enterprises to do risk assessments for chemicals & enterprises to do risk assessments for chemicals & mixtures of chemicalsmixtures of chemicals

Required informationRequired information– Type of task – shoveling, drillingType of task – shoveling, drilling– Hazard classification (using risk & safety phrases Hazard classification (using risk & safety phrases

from MSDS )from MSDS )– Volatility or dustiness (from guidance material)Volatility or dustiness (from guidance material)– Amount used- kg,mg,litres,millilitersAmount used- kg,mg,litres,milliliters

HSE (UK) COSHH Essentials HSE (UK) COSHH Essentials (cont)(cont)

System identifiesSystem identifies

– Control band (control approach)Control band (control approach)

– Produces advice on controlling risk from the Produces advice on controlling risk from the chemical being used in the taskchemical being used in the task

– Provides written guidance & documentationProvides written guidance & documentation

ILO Chemical Control Tool kitILO Chemical Control Tool kit

Very similar to COSHH EssentialsVery similar to COSHH Essentials

Does not apply to process dusts or fumes due to the Does not apply to process dusts or fumes due to the fact that these are not classified by the supplier of fact that these are not classified by the supplier of individual chemicalsindividual chemicals

Has general application to many situations in Has general application to many situations in developing countries but susceptible groups (child developing countries but susceptible groups (child workers & pregnant women) need to be consideredworkers & pregnant women) need to be considered

Stages of the ILO Chemical Stages of the ILO Chemical Control ToolkitControl Toolkit

Stage 1 – Hazard ClassificationStage 1 – Hazard Classification

Stage 1 – Hazard Classification Stage 1 – Hazard Classification (cont)(cont)

Stage 2 – How Much is UsedStage 2 – How Much is Used

Stage 3 - DustinessStage 3 - Dustiness

Stage 3 – VolatilityStage 3 – Volatility

Source: ILO toolkit

Stage 4 – Control ApproachStage 4 – Control Approach

Source: ILO toolkit

Stage 5 – Task Specific Control Guidance Stage 5 – Task Specific Control Guidance SheetSheet

Source: ILO toolkit

Lessons LearnedLessons Learned

Understanding Hazard is prerequisite to risk Understanding Hazard is prerequisite to risk assessmentassessment

Risk Assessment is essential to determine degree Risk Assessment is essential to determine degree exposure controlsexposure controls

Comprehensive Risk Assessment reduces over all Comprehensive Risk Assessment reduces over all cost of exposure monitoring and provides opportunity cost of exposure monitoring and provides opportunity to implement exposure controls before monitoringto implement exposure controls before monitoring

Above all: Adds few days, months or years in to life Above all: Adds few days, months or years in to life of working people. of working people.


pdc maharshi mehta occucon

Education

degree of health risk

risk control

harm risk

apparent health risk

time risk

complete risk

risk evaluation

health hazards