ctawwa health & safety training
TRANSCRIPT
Spring 1501 - Health and Safety at Water Treatment Facilities
January 29, 2015
David P. Horowitz, P.E., CSP (@dphorowitz)Peter J. Grabowski, P.E.
■ Health & Safety– OSHA Top 10
■ Globally Harmonized System– Changes
– Implementation Dates
■ General Water Treatment Plant Hazards■ Safe Chemical Handling
– Typical treatment plant chemistries
– Initial response activities
– Tanks
■ Chemical Feed System Design– Tips for success
Safety Takeaways
■ Watch for common issues!
■ Watch your staff & contractors
■ Management of change
– Safety Data Sheets
■ The most frequent injuries in water treatment facilities are:
a. Cuts and bruises
b. Explosive and toxic gases
c. Slips and falls
d. Strains and Sprains
e. None of the above
I’m from OSHA. I’m here to help.I’m from OSHA. I’m here to help.
#10 Electrical – Systems Design
■ Electrical design■ Arc Flash (NFPA 70E)
System specific evaluations
■ Proposed equipment■ Existing equipment
■ PPE
#9 Machine Guarding
■ Engineered or structural fixes
■ Job Hazard Analysis (JHAs)
#8 Electrical - Wiring■ Permanent■ Temporary
#7 Ladders - CONSTRUCTION
■ Design considerations■ Milestone Observation
OSHA Video - Ladders
#6 Lockout / Tagout
■ System specific evaluation
■ Comprehensive energy source understanding
#5 Powered Industrial Trucks
■ PIVs■ Hoisting requirements
#4 Respiratory Protection
■ Engineer out, if possible■ Written Plan
■ Baseline physical■ Medical surveillance■ Fit testing
#3 Scaffolding -
CONSTRUCTION
■ Design considerations■ Milestone Observation
#2 Hazard Communication
■ Globally Harmonized System
■ Risk Management Planning– Chlorine Gas = >2,500 Lbs
#1 Fall Protection - CONSTRUCTION
■ Design considerations■ Milestone Observation
■ The most frequent safety hazard from the use of polymers is:
A. Attack on many types of stainless steel
B. Cause of severe burns and blindness
C. Evolution of a toxic gas
D. Extreme slipping hazard when spilled on surfaces
E. The boss scrutinizing chemical costs
Global Harmonized SystemMajor Changes
■ Training and implementation■ Hazard classification■ Labels and warnings■ Standard Safety Data Sheets
OSHA Video - GHS
Hazard Classifications
Physical Hazards
Hazard Classifications
HealthHazards
■ The goal of GHS■ Label elements and GHS pictograms■ Labeling components■ Possible sources of confusion
What’s wrong with HAZCOM
Too many systems
Too many systems Too confusingToo confusing
Too time consumingToo time
consuming Too nationally focused
Too nationally focused
What’s wrong with HAZCOM?
Lots
Sometimes the Signs Are Obvious
Sometimes They Can Be Subject to Interpretation
Or need an interpreter
Or worse
Bad stuff out there
Protect yourself
Protect others
Major ChangesThe Basics
■ Hazard classification■ Labels and warnings■ Standard Safety Data Sheets■ Training and implementation
GHS is the law
Turning a performance-based standard
Into prescriptive requirements
www.chinasmack.com
Effective Completion Date Requirement(s) Who
December 1, 2013 Training•New Label Elements•Safety Data Sheets
Employers
June 1, 2015 Manufacturer full complianceHAZCOM plans updated
Chemical ManufacturersEmployers
December 1, 2015 Distribution Prohibitions for non GHS labels
Chemical Manufacturers, Importers and Distributors
June 1, 2016 Updates to program and training based on new hazard classifications
Employers
Physical Hazard Health Hazard
HAZARD TYPES■ Physical
– Unstable Chemicals (Water Reactive)
– Flammables or Combustibles
– Explosives
– Stored at High Pressures
– Thermal Effects
■ Health– Acute– Chronic– Latency Period
PHYSICAL HAZARDS
■ May Cause Injury by Physical Action
■ Burns: Flammables, Combustibles
■ Pressure: Compressed Gasses
■ Explosions: Explosives, Reactives
Hazard Classifications
Physical Hazards
Hazard Classifications
Physical Hazards
EXAMPLES: PHYSICAL HAZARDS
■ Flammable
■ Explosive
■ Oxidizer
■ Pyrophoric
■ Unstable (Reactive)
■ Water Reactive
EXPLOSIVE
■ Sudden Release Of:– Pressure– Gas– Heat
■ When Exposed To:– Sudden Shock– Pressure– High Temperature
■ BLEVE: Boiling Liquid Expanding Vapor Explosion
OXIDIZER■ Reacts With Organic Material
■ Releases Oxygen
■ Promotes Combustion
Sodium Hypochlorite
Peracetic Acid
Oxygen
UNSTABLE (REACTIVE)
■ Unwanted Chemical Change During Normal Handling
■ May Generate– Heat– Pressure– Polymerization
■ Can Create– Fires– Explosions
WATER REACTIVE
■ Presence of Water
■ Forms a Gas That Is:– Flammable or
– Toxic
Flammable Liquid Categories
Possibility for Confusion?Flashpoint
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
NFPA / OSHA Flammable Combustible
NFPA 704 Diamond 4 3 2
EPA / DOT Flammable Combustible
GHS 1 or 2 3 4
Signal Word Danger Danger Warning
Hazard Statement
Extremely flammable liquid and vapor
Highly flammable liquid and vapor
Flammable liquid and vapor Combustible liquid
Pictogram Nothing
Possibility for Confusion?
NFPA Video - Confusion
Compressed Gasses■ Injurious due to
pressure
Ethylene Oxide
Oxygen
HEALTH HAZARDS
■ Acute– Immediate Effects
■ Chronic– Effects May Build Over Time– May Be Latency Before Recognized Effects
■ Latency Period– Period Between Exposure and Exposure Effects
OSHA Video - PELs
Hazard Classifications
HealthHazards
Hazard Classifications
HealthHazards
ACUTE EXPOSURE / EFFECTS
■ Example: Acids
■ Body Recognizes on Immediate Exposure■ Can Get Prompt Medical Attention
CORROSIVE■ A Hazardous Material That
Causes Visible Destruction Of, or Irreversible Alteration in Living Tissue at the Site of Contact
Sodium Hypochlorite
Sodium Hypochlorite Peracetic AcidPeracetic Acid
Acutely Toxic – Low Hazard■ Acutely
– Effects are “immediate”■ Toxic
– Chemical that causes harmful effects
– To target organ(s)– Effects are different
depending on target organ
■ May be Systemic– Affects almost all target
organs
Acutely Toxic – Low HazardIsopropyl alcohol
Isopropyl alcohol
DacarbazineDacarbazine
GlutaraldehydeGlutaraldehyde
AcetoneAcetone
Acutely Toxic - Ir ritant■ A Hazardous Material That Causes a Reversible
Inflammatory Effect on Living Tissue by Chemical Action at the Site of Contact
Isopropyl alcohol
Acutely Toxic – Sensitizer■ A Hazardous Material That Causes a Percentage of
the Exposed Group to Develop an Allergic Reaction After Repeated Exposure
Methyl methacrylate
Acutely Toxic – High Hazard■ Acutely
– Effects are “immediate”■ Toxic
– Chemical that causes harmful effects
– To target organ(s)– Effects are different
depending on target organ
■ High Hazards– Effects are significant– May be immediately life
threatening Ammonia
Chronic Toxic Effects■ Examples
– Carcinogens– Teratogens– Reproductive toxins
■ Health effects– Vary with chemical– Affect target organ– May not show up for
years after overexposure
Dacarbazine Glutaraldehyde
Label Elements■ Sodium hypochlorite
Label Elements
Label Elements
How to really confuse people
Turn thisTurn this
Into thisInto this
Safety Data Sheets
■ Prescriptive requirements■ Sections must be consistent■ Information dictated by GHS guidance
SDS Hazards Description
SDS Sections
■ Section 1, Identification ■ Section 2, Hazard(s) ■ Section 3, Composition/information ■ Section 4, First-aid measures ■ Section 5, Fire-fighting measures ■ Section 6, Accidental release measures ■ Section 7, Handling and storage ■ Section 8, Exposure controls/personal protection ■ Section 9, Physical and chemical properties ■ Section 10, Stability and reactivity ■ Section 11, Toxicological information ■ Section 12, Ecological information■ Section 13, Disposal considerations■ Section 14, Transport information■ Section 15, Regulatory information■ Section 16, Other information, includes the date of preparation or last revision.
What hasn’t changed
■ Exclusions and exemptions■ Elements of the HAZCOM program■ Training requirements■ Secondary container labeling■ Temporary container exclusion■ Special labeling systems
– NFPA 704– HMIS
Effective Completion Date Requirement(s) Who
December 1, 2013 Training•New Label Elements•Safety Data Sheets
Employers
June 1, 2015 Manufacturer full complianceHAZCOM plans updated
Chemical ManufacturersEmployers
December 1, 2015 Distribution Prohibitions for non GHS labels
Chemical Manufacturers, Importers and Distributors
June 1, 2016 Updates to program and training based on new hazard classifications
Employers
Conclusion
■ HAZCOM is adopting GHS■ Broad applicability – everybody is “in”■ Lots to do
– Training on GHS elements– Plans and programs need to be revised– SDS need to be developed– New labels need to be designed and implemented
Safety Issues for Water Operators■ Confined Space
– Monitoring– Definition– PRCS– Procedures
■ Lockout/Tagout– Energy Control procedures– Locks & tags– Electrical exposure
■ Fire Safety/Extinguishers– A-comb; B-electrical; C-chemical– Safe storage of flammables
■ Safe Lifting– Sizing up the lift– Back braces– Two person lifts– Lifting aids (hoists)
■ Hazard Communication– Hazard types: physical/health– Health hazards: acute/chronic– NFPA 704/HMIS– MSDS
■ Chemical Safety Information– Caustics: corrosivity– Always add acid to water– Good ventilation
Safety Issues for Water Operators■ Machine Guarding
– Power transmission– Guards & blocks
■ Walking/Working Surfaces– Housekeeping– Oils– Caustics– Ice– Ladders– Fall safety
■ Chemical Monitoring– Instruments– O2 deficiency– Combustible gas indicator– H2S
■ PPE– Safety glasses: a must!– Gloves: compatible material– Respirators– Hearing protection– Eyewashes/Showers
Safety Issues for Water Operators■ Emergency Preparedness
– Emergency action plan– Take care of yourself first– Call postings– Evacuation procedures– Buddy system
■ Accident Prevention– Signs: caution, warning, danger– Labeling containers & tanks– Pipe colors
Safe Chemical Handling and Initial Spill Response
Objectives■ Specific water treatment chemical hazards■ Means of hazard recognition
– Normal handling– Spill / release situations
■ Evaluate Risk■ Protect yourself
– Use of personal protective equipment– Safe distance / places of refuge
■ Protect others
Where to turn for hazard information?
Safety Data Sheet■ Expanded Label
Information■ Accessible■ Provide Copies During
Emergency Response– Outside Agencies– Hospitals, on Injury
Chemical Specifics■ Water Treatment
– Potassium Permanganate– Ferric Chloride– Liquid Oxygen– Aluminum Sulfate– Sodium Hypochlorite– Sodium Hydroxide– Sulfuric Acid– Chlorine
Potassium Permanganate■ KMnO4
■ Warning: corrosive, oxidizer■ Routes: eye, skin, inhalation,
ingestion■ Symptoms: irritation, possible
chemical burns, pulmonary edema, managanism
■ Hazards– Strong oxidizer (avoid combustibles,
wooden pallets, acids)– Large quantities of dust presents
inhalation hazard– Chronic neurological effects
Ferric Chloride■ FeCl3
■ Warning: corrosive, harmful■ Routes: eye, skin, ingestion■ Symptoms: skin irritation,
possible skin burns■ Hazards
– Slightly acidic depending on concentration
– Serious harm to eyes if splashed– Vomiting after swallowing– Large exposures cause cadiovascular
distress– Toxic on liver and kidneys
Liquid Oxygen■ O■ Warning: gas under
pressure, oxidizer■ Additional: cryogenic liquid
causes frostbite■ Hazards
– Additional oxygen causes fires to burn more violently
– Frostbite can cause severe injury including loss of skin, fingers, etc
– Compressed gas cylinders can overpressure, causing explosions
Aluminum Sulfate■ Al2(SO4)3
■ Warning: irritant■ Routes: eye, skin,
inhalation, ingestion■ Symptoms: irritation,
shortness of breath, vomiting, diarrhea
■ Hazards:– Avoid ingestion– Hydrolyzes in water forming
sulfuric acid
Sodium Hypochlorite■ NaClO■ Warning: oxidizer, corrosive
(caustic)■ Routes: eye, skin, inhalation,
ingestion■ Symptoms: irritation, chemical
burns, blood disease on chronic overexposure
■ Hazards– Reaction could generate chlorine gas– Extremely slippery– Oxidizing will cause accelerated
burning
Sodium Hydroxide■ NaOH■ Warning: corrosive
(caustic)■ Routes: eye, skin,
inhalation, ingestion■ Symptoms: irritation,
chemical burns, hair loss■ Hazards:
– Extremely slippery– Difficult to remove– Reacts with acids
Sulfuric Acid■ H2SO4
■ Warning: corrosive■ Routes: eye, skin, inhalation,
ingestion■ Symptoms: irritation, chemical
burns, pulmonary edema■ Hazards
– Highly reactive / generates fumes– Inhalation effects may be delayed– Neutralization enhances the reaction– Adding water may not be effective
Chlorine Gas / Liquid
■ Corrosive / toxic by inhalation– Vapors condense to form hydrochloric acid– Toxic at relatively low airborne concentration– Can cause pulmonary edema
■ Cryogenic as a liquid■ Reactives
– Ammonia and fuel gas– Explosive compounds
■ Strong odor, good warning properties
Chemical Emergency Response
Now we really have a problemNow we really have a problem
THREE C’s
■ Actions– Remember your priorities– Separate personnel from the hazard– Assess risk– Respond within your capability– Notify the chain of command– Follow your Emergency Response
Plan
Core Objectives
Don’t get tunnel vision
■ Chemical– Physical hazards– Health hazards– Incompatibles– Ignition sources– Heat
■ Other hazards?
Bad Things Usually Happen
Fires
Explosions
ToxicGases
Acids Caustics
Sulfuric acidAluminum sulfate
Sodium hydroxideSodium hypochlorite
VS
Exothermic! Heat, fumes, spattering materials, pressure, fire
Incompatible Reactions
Corrosive Oxidizer
Sulfuric acidAluminum sulfate
Sodium hypochloriteChlorine
Permanganate
VS
Heat, explosion, toxic gas (chlorine)
Incompatible Reactions
Fuels/Solvents Oxidizer
GasolineDiesel fuel
Paint thinner
Sodium hypochloriteChlorine
Permanganate
VS
Violent reaction, heat, explosion
Incompatible Reactions
Incompatible Reactions
Alcohols Corrosive
Methanol Sulfuric acidChlorine
VS
Heat, explosion
KEYS TO SAFE RESPONSE
■ Discipline
■ Command
■ Management
■ Don’t Let Time Become
Your Enemy
■ Don’t Cut Corners
Respond Within Your Capabilities■ First Responders –
Operations Level– Defensive containment– From a safe distance
■ Technician Level– Aggressive operations– Appropriate equipment and materials
are in-place
Annual refresher training required
Annual refresher training required
Response Procedure
■ ER Coordinator ensures incident is properly reported– Local organizations– State environmental agencies– State health agencies
■ Communications coordinator to place internal organizations on standby– Responders– Supervisors– Quality control
Actions At The Scene■ ER Coordinator
– Directs responders– Liaison to incident commander– Maintains records at the scene
■ Response– Based on threat to public safety
and treatment system
Response To Threats To Public Safety
■ Actions– Inform appropriate internal organizations– Mobilize resources to the scene– Initiate containment activities to protect critical infrastructure– In concert with Incident Command
Site Activities
■ Assessment of conditions■ Identify trapped or injured
personnel■ Ensure appropriate notification■ Isolate environmental receptors
– Water– Ground
■ Containment and curtailment■ Defensive measures
Isolate Environmental Receptors
■ As far away as reasonably possible
■ Direction of spill migration■ Drains, doors, etc.■ Spills vs releases
Site Conditions■ Do not contact spilled materials■ Illumination■ Heat■ Protrusions■ Physical activity■ Limited time■ Use of stairs and ladders■ Vision■ Communication
Conclusions / Key Points
■ Employee responsibilities– Know the chemical hazards– Use controls to prevent exposure– Review MSDS / SDS during non-routine tasks– Take action if symptoms of overexposure are felt
■ Response– Know the 4 core objectives– Chemicals can behave very differently when out in the open– Don’t take anything for granted– Get away and get the right resources to the situation– Mistakes can be costly
Storage Tank Update
West Virginia News
■ Tank Trouble– Elk River, WV
» 400,000 w/o water» January 10, 2014
– Laurens, SC» Mystery oil spill
– Belgrade, Montana» Tank fire
– Bryan, OH» Massive bird kill
Storage Tank Update
Storage Tank Update
■ Typical Tank Uses– Fleet fueling– Facility heating– Generator fueling
■ Underground Tanks– USTs– Fuel tanks need operators
■ Aboveground Tanks– ASTs– Receiving scrutiny
Remote Spill Box/FillFuel Dispenser
Fuel Pump
Interstitial Leak Detection
Spill Kit
Normal Vent
Labels
Dispenser Hose Bollards
Secondary Tank Emergency Vent
Primary Tank Emergency Vent
Mechanical Gauge
Preventive Limiting Barrier
Concrete Pad
1.5-inchesNut
Integral Containment
Rain Shield
Ideal Installation – Generator Tank
What’s the best way to respond to a spill?
PREVENT IT FROM HAPPENING!!
Common Chemical Uses
■ Coagulation■ Filter and Floc Aids■ Taste and Odor
Control■ Disinfection■ pH Adjustment■ Fluoridation■ Corrosion Control
Chemical Feed System Designs■ Good Engineering
Practices– Regulatory Agencies– Utility Standards– Operator Preferences– Economics– Spatial Constraints
Design Considerations/Flexibility
■ Bulk Tanks■ Transfer Pumps■ Day Tank■ Metering Pumps■ Containment
Chemical Compatibility■ ALWAYS check wetted material for
compatibility■ Effect Ratings
– None – excellent– Minor – good– Moderate – fair– Severe – not recommended
■ Resistance Charts
Delivery Area Containment
Bulk Tank Sizing■ Typical Sizing
– Avg. dosage– Max. flowrate– 30 to 45 days
■ Chemical Stability
■ EPCRA
Bulk Tank Options/Appurtenances
■ Number of Tanks■ Monitoring
– Automatic level indication– Visual sight tube
■ Discharge Motorized Valve
■ High Level Alarm/Audible Horn
■ Filter Canister
Transfer Pump Design Considerations
■ Fill Time■ Flooded Suction■ Compatible Material■ Viscosity of the
Chemical■ Siphoning
Day Tank Options/Appurtenances
■ Electronic Load Cell
■ Sight Tube■ Automatic Level
Indication■ High Level Switch■ Remote
Monitoring
Metering Pump Design
■ Concentration■ Specific gravity■ Viscosity■ Temperature■ Suction Lift or
Flooded Suction■ Injection
Pressure
Chemical Feed System Operation
■ Best Management Practices
■ Standard Operating Procedures
Secondary Containment
■ Concrete Berms with Coating
■ Secondary Containment Pallets
■ Fabricated Containment Systems
■ 110% of Largest Bulk Tank
Chemical Fill Connections
■ PE Buckets■ FRP Enclosures■ PE Enclosures
Containment Options
■ Coating System– Engineering fabric– Mil thickness
■ Fill Containment■ Sump with Pump■ Sump with Float Switch■ pH Neutralization System
Safety Takeaways
■ Watch for common issues!
■ Watch your staff & contractors
■ Management of change
– Safety Data Sheets
Questions
David P. Horowitz, P.E., CSPPeter J. Grabowski, P.E.
Tighe & Bond53 Southampton Rd.Westfield, MA 01085
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