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ANNUAL REPORT & ACCOUNTS HEALTH AND SAFETY LABORATORY 2003/2004 AN AGENCY OF THE HEALTH & SAFETY EXECUTIVE

ANNUAL REPORT AND ACCOUNTS 2003/2004HEALTH AND SAFETY LABORATORY

HEALTH AND SAFETY LABORATORY

BROAD LANESHEFFIELD S3 7HQUNITED KINGDOM

PRINTED IN 2004

DESIGN_WWW.PURPLECIRCLE.CO.UK

T 0114 289 2000F 0114 289 2500E [email protected] www.hsl.gov.uk

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CONTENTS

04 About HSL

05 Milestones

06 Foreword

08 Achievements

CASE STUDIES

10 CASE STUDY 01Small scale fracturetoughness specimens forstructural integrityassessment

12 CASE STUDY 02Gas turbine safety

14 CASE STUDY 03Arsenic species in urine

16 CASE STUDY 04Geographical informationsystems and societal risk issues

18 CASE STUDY 05Occupational asthma - a national study of clinical practice and patients’ perspective

20 CASE STUDY 06Video as a riskcommunication tool

22 CASE STUDY 07Detonation resistance ofammonium nitrate

24 CASE STUDY 08Exposure to diesel engine exhaust emissions in mines

26 Operating & FinancialReview

27 Foreword to the Accounts

32 Accounts

35 Notes to the Accounts

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HSL IS AN AGENCY OF THEHEALTH AND SAFETYEXECUTIVE (HSE).

WE ARE BRITAIN’S LEADINGOCCUPATIONAL HEALTH AND SAFETY LABORATORY.

WE ARE COMMERCIALLYINDEPENDENT AND HAVE AREPUTATION FOR OBJECTIVEAND IMPARTIAL RESEARCHAND ADVICE.

WE EMPLOY ABOUT 350PEOPLE, THE MAJORITY OFTHEM SCIENTISTS ANDTECHNICIANS, ON TWO SITESIN SHEFFIELD AND BUXTON.

WE ARE A CUSTOMER-FOCUSED ORGANISATIONCOMMITTED TO TRAININGAND DEVELOPING OUR STAFF.

HSL VISION

HSL must be a world classhealth and safety laboratoryoperating as a successfulcommercial entity with adiverse portfolio of work andcustomer base, offering an attractive career for all employees.

HSL MISSION

To generate, interpret andprovide scientific informationrelevant to the control of risksto people’s health and safetyfrom work activities.

HSL SHARED VALUES

• We take pride in our workand in HSL

• We value, respect,support and encourage all HSL colleagues

• We enhance and promotethe reputation andcapabilities of HSL

• We value diversity and we support equal opportunities.

HSL BRAND IMAGE

• HSL is easy to deal with,values its customers andmeets their needs

• HSL is an independent provider of information and solutions to health and safety problems

• HSL takes pride in its corporate knowledge and quality science

• HSL provides value for money

• HSL is a consistent,professional organisation capable of rapid responseand a multi-disciplinaryapproach.

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ABOUT HSL


5

MILESTONES1911Government agrees to fundan experimental station atEskmeals in Cumberland forthe investigation of explosionsin coal mines.

1921The establishment of the Safety in Mines Research Board.

1924Acquisition of the Harpur HillBuxton site for mining safetywork on a large scale.

1928Opening of centrallaboratories in PortobelloStreet, Sheffield.

1947Formation of the Safety in Mines ResearchEstablishment (SMRE) as part of the Ministry of Fueland Power, bringing togetherthe work at Sheffield and Buxton.

1957Opening of a new laboratory in Red Hill, Sheffield, tohouse engineering and metallurgical work.

1959Formation of the OccupationalMedicine Laboratory (OML),located in central London.

1965Opening of second laboratoryin Red Hill, Sheffield, withprovision for breathingapparatus studies, generallaboratories, library andconference facilities.

1966Formation of the OccupationalHygiene Laboratory (OHL)by the Factory Inspectorate,located in central London.

1973Relocation of theOccupational MedicineLaboratory and OccupationalHygiene Laboratory toCricklewood, North London.

1975Formation of the Health and Safety Executive (HSE).SMRE, OHL and OML merge to form HSE’s Research andLaboratory Services Division(RLSD) to cover work fromacross a wide range ofindustrial health and safetytopics. RLSD adopts a threelaboratory structure:

• The Occupational Medicine and Hygiene Laboratory (OMHL) (at Cricklewood,North London)

• The Safety Engineering Laboratory (SEL) (atSheffield and Buxton)

• The Explosion and FlameLaboratory (EFL) (at Buxton)

1992Transfer of OMHL fromCricklewood to the purposebuilt Robens Building in Sheffield.

1995The restructuring of thethree laboratories into a singleintegrated laboratory, theHealth and Safety Laboratory(HSL) which becomes anagency of HSE.

2002Work, funded under thePrivate Finance Initiative,begins on constructing a newlaboratory on the Buxton siteto accommodate all of HSL.


6


CLIVE JACKSONPLANNING &

ADM

INISTRATION

NORMAN W

ESTOPERATIONS

7

I am pleased to report anothervery successful year in whichwe achieved all of our AnnualPerformance Agreementtargets. We generated asurplus of £2.241m giving anaccumulated surplus of£13.735m built up over thelast few years. Over the nextfew years this surplus will beused to offset anticipatedtransitional costs relating tothe move to the new buildingon our Buxton site. For thefirst time we broke the £3mbarrier on non-HSE revenue. The customer satisfactionsurvey, which was conductedby ORC International, showedthat 89% of customers weresatisfied with the service theyreceive compared with 88%two years ago. There weremany positive statements inthe ORC report from whichHSL can derive satisfaction.The report also highlightedareas for improvement whichwe shall be working on.

The construction of the newlaboratory is proceeding toplan. The majority of thespecialist facilities have beeninstalled to our satisfactionand detailed plans for thephysical move are wellunderway. Staff are scheduledto begin the move at the end of this October. Designvariations have been verytightly controlled and theirnet cost is likely to be close to zero. On the down side,discussions with HM Treasuryhave clarified the accounting treatment. This has had thevery unfortunate effect ofadding about £3.7m to HSL’s annual costs. We planto offset this cost largely by expanding our non-HSE business.

In response to the ScienceAudit which took place at the end of 2002, we haverevamped our InvestmentResearch Programme. Thisnow includes four major,three year initiatives onalternative fuel technologies,in vitro toxicology,occupational health, andworkability. In HSL’sjudgement these topics will be major health and safetyissues before long, and ourpreparedness will result inmajor opportunities.

There were two RIDDORevents during this year, one ofwhich resulted in a seriousfoot injury to a member ofstaff. HSE investigated thisincident and served HSL witha Crown Improvement Noticewhich HSL discharged by thedue date. HSE also carried outa safety audit of HSL’s Buxtonsite. Many positive pointswere noted in HSL’smanagement of safety,together with a number ofrecommendations. HSL alsotried out HSE’s Safety ClimateTool and made suggestionsfor its improvement. I believethat all of these safetyinitiatives will lead to furtherimprovements in health andsafety at HSL.

The Health and SafetyCommission (HSC) haspublished its new strategy.This establishes the healthand safety agenda for the UKas a whole and makes clearthat success by HSE can onlybe achieved by workingthrough and with others.HSL’s work with non-HSEcustomers is entirelyconsistent with this strategy,and our avowed intention ofsignificantly increasing ournon-HSE business will be amajor contribution to thesuccess of the strategy.

The new agenda will alsorequire changes to be made inHSL’s capabilities and indeedwe are already making thosechanges. A greater emphasison behavioural and healthsciences is expected and we have already expanded our capabilities in these areas of expertise.

The year 2004/05 will bedemanding: it is the year thatwe finally make the move toour new laboratory; deliveringHSC’s strategy will result infurther change; we need tosignificantly increase our non-HSE business and continue todo so whilst still meetingHSE’s needs. However, I amconfident that HSL’s staffhave the skill and motivationto succeed in all theirendeavours. Our previousyears have all been highlysuccessful and there is noreason why 2004/05 should be any different.

FOREWORD Dr DAVID BUCHANAN FREng

DAVID BUCHANAN

CHIEF EXECUTIVE

JOHN VERNEY

FINANCE


8

ACHIEVEMENTSTO IMPLEMENT BY APRIL 2004 THERECOMMENDATIONSFROM THE INDEPENDENTSCIENTIFIC AUDITUNDERTAKEN IN LATE 2002.

ACHIEVEDIn response to the fourspecific recommendationsmade by the audit team,HSL has:

• prioritised the actionsidentified in its S&TStrategy and implementedthese through existingplanning processes. In particular, HSL hasrevamped its InvestmentResearch Programme, whichnow includes four major,three year initiatives onalternative fuel technologies,in vitro toxicology,occupational health,and workability;

• reviewed and widened itspolicy on publications;

• improved its intra-laboratorycommunications of technicalissues through, for example,a revitalised programme oflunchtime technicalseminars, cross-group‘research in progress’meetings and the use oftopic-based forums on theintranet; and

• considered how to put inplace exchange programmesfor scientists to visit otherlaboratories for extendedperiods. There are, however,significant difficulties to be overcome relating to terms and conditions of employment, and these are being given further consideration.

TO UNDERTAKE SCIENTIFICAUDITS OF A TRADITIONALAREA AND A NEW AREA OFACTIVITY BY EARLY 2004.

ACHIEVEDIn January 2004 a team offour senior scientists andengineers from the UK andUSA reviewed four technicalareas of HSL’s work:computer modelling,particularly ComputationalFluid Dynamics and FiniteElement Analysis; metallurgyand materials; and aspects of occupational hygiene(exposure control andminerals and fibres). The HSLBoard is considering the auditteam’s recommendations.

TO COMPLETE AT LEAST 95%OF INCIDENT INVESTIGATIONSTO CUSTOMERS’ SATISFACTIONON TIMELINESS AND QUALITY.

ACHIEVED97%.

TO INVESTIGATE VFM VIA ANINDEPENDENT CUSTOMERSATISFACTION SURVEY.

ACHIEVEDORC International undertookan independent survey ofcustomer satisfaction onbehalf of HSL in January2004. HSL achieved a highlevel of overall satisfaction(89%). On overall value formoney, of those respondentswho had experience of othersuppliers, just over threequarters of them felt thatHSL’s services comparedfavourably with otherlaboratories; 97% felt thatHSL provided better value interms of its knowledge and expertise.


9

THE CONSTRUCTION OF THE NEW LABORATORY IS PROCEEDINGTO PLAN. THE MAJORITY OF THE SPECIALIST FACILITIES HAVEBEEN INSTALLED TO OUR SATISFACTION AND DETAILED PLANS

FOR THE PHYSICAL MOVE ARE WELL UNDERWAY.

TO RECOVER FULL ECONOMICCOSTS ON AN ACCRUALSBASIS, TAKING ONE YEARWITH ANOTHER.

ACHIEVEDDuring this period, HSLgenerated sales of£25,469,000 against netcosts of £22,861,000 toachieve an operating surplusof £2,608,000. HSL made asurplus for the financialyear of £2,241,000 afterdeducting interest payableand similar charges.

TO MEET THE AGREED NETADMINISTRATION COSTSFINANCIAL CONTROL POSITION.

ACHIEVEDIn 2003/04 HSL met the agreed net administration costs financial control position.

TO ACHIEVE INCOME FROMNON-HSE CUSTOMERS OFABOUT £2,750K BUT MAKINGDUE ALLOWANCE FOR HSE DEMAND.

ACHIEVEDScience and Technologyincome in 2003/04 fromnon-HSE customers was£3,103,000.

TO PUT IN PLACEARRANGEMENTS TO ACHIEVEA SUBSTANTIAL INCREASE ININCOME FROM NON-HSECUSTOMERS IN 2004/05.

ACHIEVEDFollowing a thorough reviewof its Marketing Strategy,HSL has identified four keymarket sectors for non-HSEbusiness and is implementingdetailed plans for each ofthese sectors. A number ofbusiness developmentscientists have been recruited.Their task is to develop anddeliver new opportunities inspecific areas.


10

OVER A PERIOD OF TIME MANY STRUCTURESDEVELOP CRACK-LIKE DEFECTS AND AN

ENGINEERING-CRITICAL ASSESSMENT MAY BENEEDED TO ENSURE THE CONTINUED SAFETY OF

THE CRACKED STRUCTURE.

CASE STUDY


11

In many industrial situationsageing equipment must beassessed to demonstrate its continued integrity.Examples include onshoreand offshore process plant.This assessment is madedifficult, in many cases, by alack of adequate data.

Over a period of time manystructures develop crack-likedefects and an engineering-critical assessment may beneeded to ensure thecontinued safety of thecracked structure. To do this,data are required relating to the applied stresses, bothstatic and cyclic; the size andnature of cracks; and thebehaviour of the material inthe presence of cracks. Thelast of these is defined by the material’s fracturetoughness and can bemeasured using standard laboratory specimens.

For many existing structures,fracture toughness data donot exist and cutting out largesections of material from anexisting structure to obtainfracture toughness specimenswould itself reduce theintegrity of the structure. It is possible to extract smallamounts of material from,say, a vessel wall withoutcompromising its integrity.However, the fracturetoughness specimens that aremanufactured from such asample are very much smallerthan those allowed bystandard test methodologies.

In a project funded jointly by HSE and industry, HSLexplored the possibility ofobtaining useful data fromspecimens as small as 5mmby 5mm in cross section. Theanalytical technique used isbased on obtaining areference temperature whichcharacterises the fracture

toughness of materialsundergoing a ductile to brittletransition. Experimentalresults were used to define amaster curve which describedthe shape and position of theductile to brittle transition.Fracture toughness of thelarge, conventional specimenscould thus be predicted fromthe small ones.

The results of this work,on more than 350 specimens,have clearly demonstrated thevalidity of the approach tohomogeneous material. Thefindings have been widelypublicised in the UK andEurope. Further research is currently underway toassess the method on morestructurally relevant andstatistically variable weld materials.

BILL GEARY

SMALL SCALE FRACTURE TOUGHNESS SPECIMENS FOR STRUCTURAL INTEGRITY ASSESSMENT

CASE STUDY

01JOH

N DUTTON

IN A PROJECT FUNDED JOINTLY BY HSE AND INDUSTRY, HSL EXPLORED THEPOSSIBILITY OF OBTAINING USEFUL DATA

FROM SPECIMENS AS SMALL AS 5MM BY5MM IN CROSS SECTION.


12

Natural gas is the primaryfuel for industrial gasturbines which are the mainsource of electricitygeneration in the UK. Gas turbines are usuallyhoused in an acousticenclosure to reduce noiseemissions. Ventilation isprovided to both cool theturbine and prevent thedangerous build-up of gas inthe event of a leak. If theventilation is not effective anexplosion hazard could arise.Computational FluidDynamics (CFD) modelling isthe main means by which the effectiveness of theventilation can be assessed.

In anticipation of the need for new gas turbine plant tocomply with the requirementsof the ATEX Directives afterJune 2003, HSL initiated amajor research project for this

industrial sector. The EuropeanDirectives relate to the healthand safety of workerspotentially at risk fromexplosive atmospheres and to the design and manufactureof equipment such as gasturbines. The main aim of thistwo year project, which wasjointly funded by HSE and 28industrial sponsors, was toprovide a well-substantiatedmeans for operators ofindustrial gas turbines todemonstrate compliance withthe ATEX Directives.

The project has quantified theexplosion hazard created in aseries of experimental trialsin large explosion-proof rigsat HSL. CFD simulations atHSL, with additional inputfrom three of the main CFDsoftware suppliers, have beencompared to experimental gasconcentration measurements

as a means of validating keyaspects of the modellingtechnique. The combinationof experiment and CFD hasled to a revised ventilationsafety criterion for theindustry. This new criterionremoves unnecessaryconservatism, whilst stillretaining a margin of safety.

Best practice guidance in the application of CFD, andthe conduct of in-situmeasurements in acousticenclosures, has also beenprepared by HSL in closeconsultation with the projectsponsors. The project is alsoinfluencing the drafting of an ISO standard on gasturbine safety.

MAT IVINGS

GAS TURBINE SAFETY

CASE STUDY

02

THE COMBINATION OF EXPERIMENT AND CFD HASLED TO A REVISED VENTILATION SAFETY CRITERIONFOR THE INDUSTRY. THIS NEW CRITERION REMOVES

UNNECESSARY CONSERVATISM, WHILST STILLRETAINING A MARGIN OF SAFETY.


13

THE PROJECT HAS QUANTIFIED THEEXPLOSION HAZARD CREATED IN A SERIES OFEXPERIMENTAL TRIALS IN LARGE EXPLOSION-

PROOF RIGS AT HSL.

CASE STUDY


14

THIS NEW METHOD OF ANALYSIS GIVESMORE INFORMATION ABOUT THE TYPE OF

EXPOSURE TO ARSENIC, AND WILL HELP TOIMPROVE RISK ASSESSMENTS FOR

ARSENIC IN AND OUT OF THE WORKPLACE.

LOW TOXIC, ORGANIC FORMSSUCH AS ARSENOBETAINE AREFOUND IN DIETARY SOURCES,

ESPECIALLY SEAFOOD.

CASE STUDY


15

The toxicity and biologicalactivity of arsenic isdependant on its chemicalform and oxidation state, aswell as the amount present.Inorganic species of arsenicare more toxic than organicforms, and trivalent inorganicarsenic is more toxic thanpentavalent inorganic arsenic.Low toxic, organic forms suchas arsenobetaine are found indietary sources, especiallyseafood. The more toxicforms of inorganic arsenic-containing compounds arewidely used in industry; forexample, in the manufactureof glass, in the semi-conductorindustry and in woodpreservatives. Occupationalexposure in such industriesmay lead to skin disorders,and over a period of exposureto sub-acute gastrointestinaland nervous systemdisturbances. The WorldHealth Organisation classifiesarsenic as a humancarcinogen and arseniccompounds have maximumexposure limits.

Arsenic is mostly excreted in urine and this is used forbiological monitoring ofoccupational exposure.However, to assess more fullylevels of exposure and

potential risks, the differentspecies of arsenic along withthe dietary contributionshould be considered.

HSL has developed a newmethod for urinary arsenicmeasurement that allows theseparation of five individualspecies: trivalent inorganicarsenic; pentavalent inorganicarsenic; the metabolites ofarsenic, dimethylarsinic acidand methylarsonic acid; andarsenobetaine. The methoduses liquid chromatographyto separate the species anddetects them with aninductively coupled plasmaemission mass spectrometer.

Recent work at HSL has beenused to establish levels ofindividual arsenic species inurine samples from workersin the timber treatment andsemiconductor industries, andfrom a control group ofpeople not occupationallyexposed. The effect of seafoodon the arsenic levels in urinewas also investigated. In thiscase volunteers collected aurine sample having eaten noseafood for three days andthen a second sample 24hours after eating seafood.

The results showed a four-fold increase in urinaryarsenobetaine 24 hours aftereating seafood. Increasedlevels of dimethylarsenic acidwere also found. No toxicinorganic arsenic species wereseen in the samples from the control group.

Concentrations of dietary-related arsenic species insamples from workers weresimilar to the control groupwho had not eaten seafood.Toxic inorganic arsenicspecies were found in smallamounts in samples from thesemiconductor workers, andin more significant amountsin the timber treatmentworkers. For timber treatmentworkers, 80% of the arsenicwas occupationally relatedand only 20% was fromdietary sources.

This new method of analysisgives more information aboutthe type of exposure to arsenic,and will help to improve riskassessments for arsenic in andout of the workplace.

JACKIE MORTON

ARSENIC SPECIES IN URINE

CASE STUDY

03


16

A Geographical InformationSystem (GIS) is a set ofsoftware tools which can beused to input, store, analyse,manipulate and display datawith a spatial component. A GIS combines digitalcartographic and ComputerAided Design capabilities andintegrates these with databasesoftware to provide apowerful and versatile tool foruse with a wide variety ofdata. For example, a user’sown data can be combinedwith geographical, land use orhydrological maps; transportnetworks; and locational,address and census data. A GIS is able to interrogatethese data sets and providesophisticated analysis andthematic maps, which canprovide a unique perspectiveon a problem.

HSL is a member of theOrdnance Survey (OS) PanGovernment Agreement forthe supply of digital mappingproducts. This allows access

to the wide range of OSbusiness products, including1:250 000, 1:50 000 and1:10 000 scale mapping andthe OS specialist productsused for locating addressesand infrastructurenationwide. HSL also has anational holding of the OS’slarge scale vector mappingproduct, MasterMap. Accessto these and other productshas enabled HSL to provide state of the art GIS support to HSE for a wide variety ofprojects, including support for major hazard land-useplanning decisions and risk assessments.

A recent piece of work forHSE examined societal riskissues. This focused onchemical plants with largeinventories of hazardousmaterials and the risk offatalities associated with arange of possible releasescenarios. Detailed maps were produced of thecontours of individual risk

around the chemical sites. A number of different datasets were combined to explorehow these related to changesin the surrounding populationdistribution over the past 20 years. Historical mappingdata were used to examinethe changes in land usearound the sites; thesehighlighted changes inhousing, work places andpublic land. Data sets ofcensus and populationlocation details were thenoverlaid within the GIS to examine the growth and redistribution of the population.

The resulting maps were used to explain a number ofcomplex societal risk issues in a clear and accessible way,and thus facilitate policydiscussions by the Health andSafety Commission and othergovernment departments.

HELEN BALM

FORTHH

ANNAH W

HITE

GEOGRAPHICAL INFORMATION SYSTEMS AND SOCIETAL RISK ISSUES

CASE STUDY

04

A GIS IS ABLE TO INTERROGATETHESE DATA SETS AND PROVIDESOPHISTICATED ANALYSIS AND

THEMATIC MAPS, WHICH CANPROVIDE A UNIQUE PERSPECTIVE

ON A PROBLEM.


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A RECENT PIECE OF WORK FOR HSE EXAMINEDSOCIETAL RISK ISSUES. THIS FOCUSED ON

CHEMICAL PLANTS WITH LARGE INVENTORIES OFHAZARDOUS MATERIALS AND THE RISK OFFATALITY ASSOCIATED WITH A RANGE OF

POSSIBLE RELEASE SCENARIOS.

CASE STUDY

© CROW

N COPYRIGHT. ALL RIGHTS RESERVED, HSE, 100021025, 2004


18

AFTER A YEAR, HALF OF THE CASES HAD BEENGIVEN A FIRM DIAGNOSIS OF OCCUPATIONAL

ASTHMA BY THE SPECIALIST DOCTOR.

IMAGE COURTESY OF ASTRA ZENECA

THE STUDY HAS SHOWN THAT THERE ISMUCH THAT NEEDS TO BE DONE TO IMPROVE

THE SITUATION FOR INDIVIDUALS WITHOCCUPATIONAL ASTHMA.

CASE STUDY


19

Occupational asthma remainsa common respiratory diseasein Great Britain and costssociety up to £1.1 billion each year. However, it can be prevented through theimplementation of effectivecontrol strategies in theworkplace. In 2001 the Healthand Safety Commissionagreed a package of measuresaimed at reducing theincidence of asthma causedby workplace exposures by30% by 2010. Delivery of this target requires a newapproach to tackling theproblem by both HSE andother stakeholders.

The accurate diagnosis ofoccupational asthma is relianton workers reporting work-related respiratory symptomsquickly, possibly as part ofhealth surveillance, and thenbeing referred equally quicklyto an occupational orrespiratory physician fordiagnosis and management.HSE asked HSL to undertakea national study to see how this process worked in practice.

The study involved sixspecialist centres foroccupational respiratorydisease in England, and about100 patients who were being

investigated for occupationalasthma. A nurse interviewedeach patient to collectinformation about theirsymptoms, the conditions in their workplace and thehealth and safety systems in place. Patients were alsocontacted a year later to seehow things had changed for them.

The most common route ofreferral to a specialist centrewas through the generalpractitioner (72%), with aminority being referredthrough an occupationalhealth physician (20%). The average time between the start of symptoms andreferral to a specialist doctorwas four years with amaximum of 28 years. The tests that were used tomake the diagnosis variedwidely between the six expert centres investigated.

After a year, half of the caseshad been given a firmdiagnosis of occupationalasthma by the specialistdoctor. The majority of thesepatients still had theirbreathing symptoms, andwere being given asthmatreatment. Just under half ofthe workers were still in thesame job that caused their

symptoms at the one-yearfollow-up. There is clearevidence that this will lead toa poorer long-term outcomefor the patients. The majorityof workers in the study felt letdown by their employer. They perceived that a lack of health and safety measureshad contributed to thedevelopment of theirrespiratory symptoms. Some workers had had toretrain and undertake newjobs; most had to fund this training themselves.

The study has shown thatthere is much that needs to bedone to improve the situationfor individuals withoccupational asthma. HSL isnow involved in follow-onwork aimed at trying toimprove the outcome forindividuals who have thiscondition and developingpreventative strategies.

LISA BRADSHAW

DAVID FISHW

ICKM

ANDY HENSON

OCCUPATIONAL ASTHMA - A NATIONAL STUDY OF CLINICAL PRACTICE AND PATIENTS’ PERSPECTIVE

CASE STUDY

05


20

Effective risk communicationwith employers andemployees is critical ifprogress is to be made inreducing occupational ill-health. The riskcommunication strategyadopted in any givencircumstance will varydepending on the message,the audience and the intendedoutcome. In all cases,however, the key points aboutthe risk and its control mustbe readily understood to beeffective. HSL has combinedvideo recording andsimultaneous measurementof exposure to physical and chemical agents todemonstrate potential risksto workers in a visual andeasy to understand way.

One example where thisapproach has been applied isin the study of heat stress.This condition is not alwaysperceived as a hazard and isoften accepted as part of thejob. HSE asked HSL toinvestigate the provision ofindustry-specific guidance onheat stress with the objectiveof demonstrating thatexposure to heat produceseffects that go beyond simplyfeeling uncomfortably hot.

Under hot conditions heartrate increases as the bodyattempts to thermoregulate byincreasing the blood flow tothe skin. Since heart rate canbe easily measured and ismeaningful to most people it was selected as a suitablemeasure of exposure to heat.Clearly there are otherreasons why the heart ratemight increase, such asphysical exertion, but whenthese are taken into accountany change in heart rate in ahot environment can beattributed to the thermal load.

When heart rate data wereoverlaid onto a videorecording of work activities,the direct effect of heat stresson the heart rate wasrevealed. The video footage isbeing used in training daysfor industry to show howradiant heat and a hot workenvironment can inducephysiological changes.

In a second example, HSL iscollaborating with ImperialCollege London as part of anEngineering and PhysicalSciences Research Councilproject called DAPPLE(Dispersion and Penetrationof Pollution in the Local

Environment). HSL’s role isin the assessment of personalexposure to environmentalpollution, specificallyparticulate matter and carbonmonoxide, and to evaluatehow this varies with locationand time for different modes of transport and routes of travel around astreet intersection.

A baby buggy and bicyclehave been adapted to carrymonitoring equipment and a video camera so thatexposure of members of thepublic going about theirnormal daily activities can be simulated. This videovisualisation techniqueallows the project team notonly to analyse the factorsaffecting personal exposureto pollution, but also to showpolicy makers and the publicin a highly visual way howand why exposure occurs.The methodology can alsobe applied to the exposureassessment of outdoor workers.

RODGER CLARKED SANDERSON

SHUNA POW

ELL

VIDEO AS A RISK COMMUNICATION TOOL

CASE STUDY

06


21

THIS VIDEO VISUALISATIONTECHNIQUE ALLOWS THE PROJECTTEAM NOT ONLY TO ANALYSE THEFACTORS AFFECTING PERSONAL

EXPOSURE TO POLLUTION, BUT ALSOTO SHOW POLICY MAKERS AND THE

PUBLIC IN A HIGHLY VISUAL WAYHOW AND WHY EXPOSURE OCCURS.

A BABY BUGGY AND BICYCLE HAVE BEEN ADAPTED TO CARRYMONITORING EQUIPMENT AND A VIDEO CAMERA SO THAT

EXPOSURE OF MEMBERS OF THE PUBLIC GOING ABOUTTHEIR NORMAL DAILY ACTIVITIES CAN BE SIMULATED.

CASE STUDY


22

AMMONIUM NITRATE (AN) IS THE MAJOR CONSTITUENT OF MANY

COMMERCIAL FERTILISERS, BUT UNDER CERTAINCONDITIONS IT CAN DETONATE.

CASE STUDY


23

Ammonium nitrate (AN) isthe major constituent ofmany commercial fertilisers,but under certain conditionsit can detonate. Detonation isan extremely rapid explosivedecomposition. This explosivebehaviour is the reason whythe European Union has, formore than 20 years, requiredmember states to control thestorage of AN fertiliserscontaining more than 80%of the chemical.

The devastating explosioninvolving 200-300 tonnes ofAN near Toulouse in 2001,which resulted in 29 fatalitiesand injured almost 2500people, brought the safetyrisks into sharp focus. As aresult of this explosion, theEuropean Commissionrevised the requirements forthe control of AN-basedmaterials. In 2003, theDepartment for Environment,Food and Rural Affairs(DEFRA) implemented thenew requirements in the

Ammonium Nitrate Materials(High Nitrogen Content)Safety Regulations 2003.These regulations requireevery batch of solid AN-basedmaterials, other than ANintended for use inexplosives, to be subjected tothe ‘resistance to detonationtest’. Where production of abatch extends beyond threemonths, a sample of eachthree months’ production hasto be tested.

HSL provided detailedtechnical advice to DEFRAduring the drafting of thenew Regulations and hasrecently set up a custom-designed sample preparationfacility for the resistance todetonation test. The sample isconfined in a thick-walled,100 mm diameter steel tubeand subjected to the shockfrom a powerful explosivebooster. Detonation of thesample is assessed by thedeformation of the leadblocks upon which the tube

is supported. Fertilisermaterials that fail the testmay not be supplied or storedin quantities exceeding 500kgunless they have beenreprocessed or made lessreactive to mechanical forces.

HSL is currently undertakingresistance to detonation testsunder contract to DEFRA(on behalf of Local TradingStandards Officers whoenforce the Regulations),and offers the tests on acommercial basis formanufacturers and suppliersof AN-based materials.

JAMES FLETCH

ERH

EATHER ROYLE

DETONATION RESISTANCE OF AMMONIUM NITRATE

CASE STUDY

07

THE DEVASTATING EXPLOSION INVOLVING200-300 TONNES OF AMMONIUM NITRATE NEAR

TOULOUSE IN 2001, WHICH RESULTED IN 29FATALITIES AND INJURED ALMOST 2500 PEOPLE,

BROUGHT THE SAFETY RISKS INTO SHARP FOCUS.

IMAGE COURTESY OF JEAN-PHILIPPE ARLES, REUTERS


24

Diesel powered vehicles and equipment are used invirtually all coal and non-coalmines in the UK where theyperform functions vital to theproductivity of the industry.In the relatively restrictedspace of a mine, it isinevitable that workers closeto diesel vehicles will beexposed to diesel engineexhaust emissions (DEEEs) to some extent. However,there has been no clearindication of the level of riskpresented by such exposuresor how they might becontrolled. In response tothis, HSE commissioned aprogramme of work with HSL to investigate exposureto DEEEs in mines and themethods that could be used to control them.

The first stage in the riskassessment involved themeasurement of mineworkers’ exposure to DEEEs,using a measurementtechnique developed for anearlier assessment of dieselexhaust in surface industries.Airborne particulate materialwas collected and analysedfor elemental carbon(essentially soot) and organiccarbon (the material absorbed

onto the soot). A modifiedsampler was used in the coalmines to separate dieselexhaust particulate from coaldust which would otherwiseinterfere with the analysis.

The study showed thatexposures in coal mines arecomparable with those offorklift truck drivers, thegroup with the highestexposures in the surfaceindustry survey. Exposures innon-coal mines, however,were significantly higher thanin the coal mines; in somecases, two to three timeshigher. The differencebetween the two types ofmine arises mainly from thediffering ventilation regimes.Coal mines use high volume,high velocity air movement to prevent the build up ofexplosive gases, which is also very effective at diluting and dissipating DEEEs. Non-coal mine ventilationvelocities, on the other hand,are much lower resulting inpoorer dissipation of theengine exhaust.

Two options for controllingexhaust emissions wereconsidered: changing the fuelto reduce particulate

emissions, and conditioningthe exhaust with a catalyticconverter. Ideally the twomeans of control would beused in tandem, but it wasfound that biodiesel whencombusted leaves a slightwaxy deposit which wouldclog the catalytic filter.

Most mine vehicles run onstandard diesel fuel thatcomplies with BS EN590. A study of emissions fromalternative fuels on the HSLdiesel engine test bed showedthat biodiesel derived fromrapeseed reduced particulateemissions by about 70%.Subsequent trials of biodieselin a coal mine have producedsome very encouraging results.

An exhaust treatment deviceknown as a catalytic dieselparticulate filter has also beenevaluated and has reducedparticulate emissions fromstandard diesel fuel by 90%.A trial is about to start in a gypsum mine and, ifsuccessful, may also provide a solution for non-coal mines.

DAVE DABILL

EXPOSURE TO DIESEL ENGINE EXHAUST EMISSIONS IN MINES

CASE STUDY

08


25

IN THE RELATIVELY RESTRICTED SPACE OF AMINE, IT IS INEVITABLE THAT WORKERS CLOSE

TO DIESEL VEHICLES WILL BE EXPOSED TO DIESELENGINE EXHAUST EMISSIONS (DEEES)

TO SOME EXTENT.

A STUDY OF EMISSIONS FROM ALTERNATIVE FUELSON THE HSL DIESEL ENGINE TEST BED SHOWED THAT

BIODIESEL DERIVED FROM RAPESEED REDUCEDPARTICULATE EMISSIONS BY ABOUT 70%.

CASE STUDY


26

OPERATING & FINANCIAL REVIEWThe HSL Annual Report and Accounts address many ofthe issues appropriate to HSLthat come within the scope ofthe Accounting StandardsBoard's requirements for anOperating and Financial Review.

Of particular importance is adescription of HSL's businessand aims and objectives(see pages 4 and 27), themembership of the HSLBoard (see page 27) andHSL's arrangement foraudit (see pages 28 and 31).Also of particular relevanceis the Annual PerformanceAgreement and how wellHSL has performed in2003/04 against the targetsset by HSE (see pages 8 and 9). A significant event in 2003/04 was thecommissioning of a CustomerSatisfaction Survey by ORCInternational, the third since1999, and further reference ismade to this on pages 7 and 8.

Looking to the immediatefuture, by far the mainchange influencing HSL isthe collocation, in Autumn2004, of all HSL's laboratoryactivities onto its Buxton sitein a new purpose-builtlaboratory being acquiredunder the terms of a PFIcontract (further details aregiven at pages 7 and 27).This will significantly changeHSL's land and buildingsasset base.

In respect of turnover HSL,with HSE agreement, isalso looking to increasesignificantly the level ofbusiness from non-HSEcustomers, whilst maintainingHSE business broadly atpresent levels.


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ANNUAL REPORT & ACCOUNTS HEALTH AND SAFETY LABORATORY 2003/2004 AN AGENCY OF THE HEALTH & SAFETY EXECUTIVE

ANNUAL REPORT AND ACCOUNTS 2003/2004HEALTH AND SAFETY LABORATORY

HEALTH AND SAFETY LABORATORY

BROAD LANESHEFFIELD S3 7HQUNITED KINGDOM

PRINTED IN 2004

DESIGN_WWW.PURPLECIRCLE.CO.UK

T 0114 289 2000F 0114 289 2500E [email protected] www.hsl.gov.uk

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