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For further information Contact:

Paryavaran Parisar,E-5, Arera Colony, PB No. 563,Bhopal-462 016 MP (India),Fon +91-755-2466715, 2461538, 2461348, Fax +91-755-2466653 dmi@dmibhopal.nic.inwww.dmibhopal.nic.in

Disaster Management Institute

International Weiterbildung und Entwicklung gGmbHCapacity Building International, GermanyFriedrich-Ebert-Allee 4053113 BonnFon +49 228 4460-0Fax +49 228 4460-1766www.inwent.org

InWEnt -

DMIBhopal

Theme-5

Personal Protective Equipments

NOTICEPERSONAL PROTECTIVEEQUIPMENTS REQUIRED

BEYOND THIS POINT

DisclaimerThough all care has been taken while researching and compiling thecontents provided in this booklet. DMI-InWEnt-gtz-ASEM accept noliability for its correctness.The reader is advised to confirm specifications and health hazardsdescribed in the booklet before taking any steps, suitability of actionrequires verifications through other sources also.Information provided here does not constitute an endorsement orrecommendation.

Chief Editor

Editors

Support

Published under

InWEnt

Disaster Management Institute

GTZ ASEMAdvisory Service in Environmental Management

Praveen Garg, IAS, Executive Director, DMI, Bhopal, India

Dr. Rakesh Dubey, Director, DMI, Bhopal, IndiaFlorian Bemmerlein-Lux, Sr. Advisor, InWEnt, Germany

Sudheer Dwivedi, Dy. Director, DMI, Bhopal, IndiaDr. Asit Patra, Asstt. Director, DMI, Bhopal, IndiaNeeraj Pandey, Content Manager, InWEnt IndiaAmit Kumar Dadhich, Content Manager, InWEnt IndiaHuda Khan, Content Manager, InWEnt India

InWEnt-gtz-ASEM Capacity Development Programme for industrial Disaster Risk Management (iDRM)

Edition 1, 2010

International Weiterbildung und Entwicklung gGmbHCapacity Building International, Germany Division for Environment, Energy and WaterLützowufer 6-9, 10785 Berlin, GermanyDr. Christina KamlagePhone +49 30 25487-117christina.kamlage@inwent.orgSteffi MallingerPhone +49 30 25487-116steffi.mallinger@inwent.org

Paryavaran Parisar, E-5, Arera Colony, PB No. 563Bhopal-462 016 MP (India),Fon +91-755-2466715, 2461538, 2461348, Fax +91-755-2466653 www.hrdp-iDRM.in

A-33, Gulmohar Park, New Delhi 110049Fon +91-11-26528840Fax +91-11-26537673www.asemindia.com

Imprint

gtz-ASEMThe Advisory Services in Environmental Management (ASEM) Programme, is a joint programme of the German Technical Cooperation (GTZ) and the Indian Ministry of Environment and Forests (MoEF). The German Federal Ministry for Economic Cooperation and Development (BMZ) supports several environment related projects in India through GTZ. ASEM focuses on seven major thrust areas -Sustainable Industrial Development, Sustainable Urban Development, Sustainable Consumption and Consumer Protection, Sustainable Environmental Governance and the cross cutting areas. Climate Change and Human Resource Development. Public PrivatePartnership (PPP) project with Indian and German companies contribute towards identified project activities. Detailed Information can be explored using our WEB sites:

www.asemindia.comwww.hrdp-net.in

InWEnt - Qualified to Shape the FutureInWEnt - Capacity Building International, Germany, is a non-profit organisation with worldwide operations dedicated to human resource development, advanced training, and dialogue. Our capacity building programmes are directed at experts and executives from politics, administration, the business community, and civil society. We are commissioned by the German federal government to assist with the implementation of the Millennium Development Goals of the United Nations. in addition, we provide the German business sector with support for public private partnership projects. Through exchange programmes, InWEnt also offers young people from Germany the opportunity to gain professional experience abroad.

Detailed Information can be explored using our WEB sites:www.inwent.org

Disaster Management Institute(DMI) BhopalThe Disaster Management Institute (DMI) was set up in 1987 by the Government of Madhya Pradesh (GoMP) as an autonomous organization in the aftermath of the industrial disaster in Bhopal.Since inception, DMI has built vast experience in preparation of both On-site and Off-site Emergency Management Plans, Safety Audit, Risk Analysis and Risk Assessment, Hazard and Operability Studies (HAZOP), etc.The National Disaster Management Authority (NDMA) constituted under the chairmanship of the Prime Minister selected DMI as a member of the Core Groupfor preparation of the National Disaster Management Guidelines- Chemical Disaster.It is a matter of pride that NDMA has selected DMI for conducting Mock Exercises onchemical (industrial) Disaster Management at key industrial locations in the country.The Ministry of Environment and Forests, InWEnt and gtz-ASEM Germany have recognized DMI as a Nodal Training Institutes for capacity building in industrial DisasterRisk Management.

www.HRDP-iDRM.in

MoEFThe Ministry of Environment & Forests (MoEF) is the nodal agency in the administrativestructure of the Central Government for the planning, promotion, coordination andoverseeing the implementation of India’s environmental and forestry policies and programmes.The Ministry also serves as the nodal agency in the country for the United Nations Environment Programme (UNEP), South Asia Co-operative Environment Programme (SACEP), International Centre for Integrated Mountain Development (ICIMOD) and for the follow-up of the United Nations Conference on Environment and Development (UNCED). The Ministry is also entrusted with issues relating to multilateral bodies suchas the Commission on Sustainable Development (CSD), Global Environment Facility (GEF) and of regional bodies like Economic and Social Council for Asia and Pacific(ESCAP) and South Asian Association for Regional Co-operation (SAARC) on matters pertaining to the environment.

FEDERAL REPUBLICOF GERMANY

COOPERATIONREPUBLIC OF

INDIA

FEDERAL REPUBLICOF GERMANY

COOPERATIONREPUBLIC OF

INDIA

Capacity Building InternationaleGermany

in ent

Contents

1.

2.

3.

4.

5.

6.1. 6.6.

11. Glossary

12. References

Introduction

Head Protection

Eye and Face Protection

Hearing Protection

Skin Protection

6. Body Protection

Leather Apron - Suspension Belts

7. Hand and Arm Protection

7.1. Leather Gloves - 7.7. Hand Sleeves

8. Leg and Foot Protection

8.1. Safety Boots and Shoes - 8.10. Slip-in-type Safety Boots

9. Respiratory Protection

9.1. Nominal Protection Factor - 9.3 Noteworthy point for

Respiratory Protective Equipment

10. Limitations 0f personal protective equipment

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1

1. Introduction

Personal Protection implies the provisions and use of various types of Personal Protective Equipment (PPE), such as safety boots, ear protectors, aprons, gloves. As such it may be consider as either last resort, when all other methods of protection have failed or purely as an interim form of protection until the hazard can be eliminated at source or controlled by some form of 'safe place' strategy, such as machinery guarding or the installation and use of local exhaust ventilation system. Personal Protective Equipment includes a wide range of equipment worn and used by people at work to protect then from both general and specific hazards. As such, it includes:

Head Protection: Safety Helmets, Bumps caps, Caps and Hair nets.Eye Protection: Goggles, Safety Spectacles, Hand held or freestanding screens.Face Protection: Face shields, which can be hand held, fixed to helmet or strapped to head. Respiratory Protection: General-Purpose Dust Respirators, Positive Pressure Powered Respirators, Helmet Contained Positive Pressure Respirators, Gas Respirators, Emergency Escape Respirators, Airline Breathing Apparatus, Self-Contained Breathing ApparatusHearing Protection: Ear Plugs, Ear Defenders, Muffs and Pads, Ear Valves, Acoustic Wool.Skin Protection: Barrier CreamsBody Protection: One Piece and Two Piece Overalls, Donkey Jackets, Aprons, Warehouse Coats, Body Warmer, Oilskin Over Clothing, Chemical Clothing.

Personal Protective Equipment (PPE) means any device or appliance designed to be worn or held by an individual for protection against one or more health and safety hazards.

PPE also includes: a unit constituted by several devices or appliances which have been integrally combined by the manufacturer for the protection of an individual against one or more potentially simultaneous risks; a protective device or appliance combined, separably or inseparably, with personal non-protective equipment worn or held by an individual for the execution of a specific activity; interchangeable components which are essential to its satisfactory functioning and used exclusively for such equipment.

2

Hand and Arm Protection: General Purpose Fibre Gloves, PVC Fabric Gauntlets, Gloves, Sleeves, Chain Mail Hand and Arm Protectors.Leg and Foot Protection: Safety Boots, Shoes, Wellingtons, Gaiters and Anklets.

As an employer, you must assess your workplace to determine if hazards are present that require the use of personal protective equipment. If such hazards are present, you must select protective equipment and required workers to use it, communicate your protective equipment selection decisions to your workers, and select personal protective equipment that properly fits your workers. You must also train workers who are required to wear personal protective equipment on how to do the following:

Use protective equipment properly, Be aware of when personal protective equipment is necessary, Know what kind of protective equipment is necessary, Understand the limitations of personal protective equipment in protecting workers from injury, Put on, adjust, wear, and take off personal protective equipment, and Maintain protective equipment properly.

2. Head Protection

There are four widely used types of head protection:

Crash Helmets; protect against impact with moving objects Industrial Safety Helmets; protect against falling objects or impact with fixed objects Bump Caps; protect against scalping or entanglement Caps and Hair nets; protect scalping or entanglement

Much will depend upon type and form of the risk an individual is exposed to in terms of head protection required. For head protection to be suitable, it must fit the wearer properly, be of an appropriate size and have an easily adjustable headband, nape and chin strap. An ideal head protection does not hinder the work being done, and has compatibility with other PPE, such as ear and eye protectors, being worn at the same time. The sizes in which industrial helmets are available in the market:

TypeHead Band SizeSmall500 -540 mmMedium540 -590 mmLarge590 -640 mmCaps have adjustable lace arrangement.

3

Orange six point ratchet suspension safety helmet with nylon webbing, Ear Muffs, Visor Bracket and Nylon Visor.

Safety signage should be displayed in those areas where the hard hat is required.

3. Eye and Face Protection

Eye protection serves to guard against the hazards of impacts, splashes from chemicals or molten metal, liquid droplets (chemical mists and sprays), dusts, gases, welding arcs, non-ionising radiation and the light from lasers. There are four principal forms of eye protection:

Safety Spectacles, which may incorporate optional shields, with lenses manufactured in tough optical plastic, such as polycarbonate, and available with standard or prescription lenses.

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5

Eye shields designed with frameless one-piece moulded lens. Safety goggles manufactured with toughened glass lenses or wide vision plastic lenses, with flexible plastic frame and elastic head band. Face shields, which are fitted with adjustable head harness, and provide protection to the face as well as the eyes.

These lenses of eye protectors must be kept clean as dirty lenses restrict vision which may cause fatigue and may be contributing feature in accident.

4. Hearing Protection

The hearing protection must be in use where exposure to noise level of 90dbA or above exists. Before use it must be ensured that the form of hearing protection chosen would produce the necessary attenuation (Sound Pressure Reduction) at operator's ear.

(a) Side shield type, net type, fitted with blue or clear lenses (b) Panorama, Leather mask, Gas cutting goggles (c) Asbestos hood, Aluminised hood (d) Plastic face shield, welding head shield, welding hand shield

Mandatory sign for face shield Safety signage should be displayed in those areas where

the eye protection is required

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4.1 Ear Plugs

These are manufactured in plastic, rubber, glass down or combination of these materials and are fitted in to the auditory canal. If fitted properly they may attenuate the noise reaching ear by 25-30dBA. They may be of the permanent or disposable type. Training for method of insertion in to ear canal is must. These provide ample protection in the work environment with noise level of 155-120dBA. Recent development is polymer foam which gives effective fitment without any pain or strain in the ear.

4.2 Ear defenders, Muffs and Pads

These cover whole ear and can reduce exposure by up to 50dBA at certain frequencies. They can be uncomfortable in hot conditions and may be difficult to wear with safety spectacles or goggles. These provide ample protection against sound level of 130-135dBA.

4.3 Ear valves

These are inserted in to auditory canal, in theory, allow ordinary conversation to take place while preventing harmful noise reaching ear.

Safety signage should be displayed in those areas where the hard hat is required

There are many chemical substances which cause dermatitis and are more commonly used in the work places. These include strong acids and alkalis, chromates and dichromate, formaldehyde, organic solvents, resins, certain adhesives, suds, degreasing compounds and lubricants. Paraffin and trichloroethylene removes the natural fats from the skin and render it vulnerable to damage from other substances.

A range of barrier creams is available to meet varying work conditions. The selection shall be based upon the chemical to be handled. They provide skin protection in wet conditions, and for workers handling acids, alkalis and other potentially hazardous substances. The barrier creams must be applied before commencement of work.

5. Skin Protection

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6.5 Safety Belt and Harness

6.6 Suspension Belts

Person working at the height of 10ft (02m) or above must use safety belt. It provides protection against fall from height.

For application where it is not possible to work from a fixed surface and the worker must be totally supported by suspension harness e.g. Shipboard painting, stack maintenance etc.

Mandatory sign for body belt

7

6. Body Protection

6.1 Leather Apron

6.2 Asbestos Apron

6.3 PVC Apron

6.4 Lead Apron

A wide range of protective clothing for the body is available, including:

Coverall, Aprons; protects against chemicals & hazardous substances Outfits to protect against cold, heat and bad weather Specific clothing to protect against machinery, such as chain saws High Visibility clothing Life jackets and buoyancy aids

In the selection of body protection, the following factors are relevant;

The degree of personal contamination from the task or process e.g. dust, Oil, General Soiling, Chemicals and other hazardous substances etc. The ease, cost or washing or dry cleaning The degree of exposure to temperature and humidity variations Possible discomfort etc.

These provide protection against the sharp objects, hot chips, oil spillages and abrasion by rough surface or objects. These are generally supplied with tapes and buckles for proper tying.

It is used to protect body from heat. These may have lint lining or leather lining, depending upon the nature of work for which they are to be used.

It is used to protect from the chemical spillages, Acid splashes, Paints and coolants.

It provides protection from the Ionising radiations e.g. X-rays, gamma rays, etc.

9

7. Hand and Arm Protection

7.1 Leather Gloves

7.2 Asbestos Gloves

7.3 Acid and Alkali Proof Gloves

7.4 Electrical Resistant Gloves

7.5 Canvas Gloves

7.6 Lead Gloves

Damage to hands and arms can arise through the use of machinery and hand tools and in manual handling operations; resulting in cuts and abrasions, through skin irritation, contact with hazardous substances and as a result of exposure to adverse weather conditions. A wide variety of hand and arm protection is available including gloves and gauntlets made of leather, chain mail, PVC fabric and man-made fibres. The gloves should not be used while working with moving machinery such as drills, saws, grinders etc. These machines may catch the gloves, pull it or with hand of worker in to the hazardous area.

Safety signage should be displayed for instruction.

These protect the hands from cuts, bruises and abrasions. Fit for handling sharp edged materials.

These provide protection to the hands from heat thereby avoid burn injuries. These gloves are provided with double-padded lining inside. These may withstand with

0temperature as high as 1000 C.

These have the black cover. These protect the workers only against the harmful effects of Acid & Alkali materials.

The colour of these gloves is Red. These protect against the electric shock. These must be purchased along with their inspection/test certificates.

These provide protection against oil, grease and other dirt.

10

These provide protection against ionising radiations like X-rays and gamma rays.

These are designed to give protection to the full length of hand (from shoulder to arm)of the wearer. Mainly used by the welders for protection against slag and metal spatterswhile doing position welding.

7.7 Hand Sleeves

(a) Canvas Gloves, Acid and Alkali proof rubber gloves, Leather Gloves, Asbestos Gloves (b) Aluminised gloves, Crust Leather Gloves (Front & Back View) (c) Safety Belt-Body harness and Life line.

Safety signage for gloves

11

8. Leg and Foot Protection

8.1 Safety Boots and Shoes

8.2 Asbestos Safety Boots

8.3 Clog

8.4 Foundry Boots

8.5 Wellington Boots

8.6 Gaiters

Safety footwear used in many industries and occupations e.g. construction, mechanical and manual handling activities, for work in cold and wet conditions, foundry work and forestry.

These are the most common type of safety footwear and commonly incorporate a steel toe cap. They can also have other safety features, such as slip resistant soles, steel insoles and insulation against extreme temperatures etc.

Used for heat radiation area. The upper part is made of asbestos; the remaining part of this boot is made of Asbestos. The remaining parts, material and construction are same as Safety boots.

Wooden clogs, frequently fitted with steel toe caps, are traditionally used in number of industries.

These incorporate steel toe caps, are heat resistant and designed to protect the foot against molten metal splashes and spillages. They are designed without external features such as laces which trap molten and commonly have elasticised sides for quick removal.

These protect against water and wet conditions and are useful in occupations where footwear needs to be washed and disinfected for hygienic reasons, such as with food industry workers. They are manufactured in rubber, polyurethane and PVC, and may feature corrosion-resistant steel toe caps, rot-proof insoles, and steel mid soles, ankle bone padding and cotton linings.

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These are commonly used in foundries to provide protection to the ankles from splashes of molten metal. They are manufactured in leather and compositions of leather, Hessian and other fibrous materials.

These prevent the build up of static electricity on the wearer. They reduce the danger of igniting a flammable atmosphere and give some protection against electric shock.

This type of footwear also prevents the build up of static electricity, and is particularly suitable for handling sensitive components or substances e.g. Explosive Detonators. It gives no protection against electric shock.

These are recommended for use by welders and also to avoid the entering of sparks inside the safety boot.

This is a combination of safety boots and leg guards; gives full protection to welders.

8.7 Anti-static Footwear

8.8 Conductive Footwear

8.9 Leg Guard

8.10 Slip-in-type Safety Boots

Aluminised Safety Boot, Asbestos Safety Boot, Gum Boot, Leg Guard, Leather Safety Boot.

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9. Respiratory Protection

9.1 Nominal Protection Factor

9.2 Forms of Respiratory Protection Equipment

The use of Respiratory Protective Equipment (RPE) is essential wherever workers are exposed to dangerous concentrations of toxic or fibrogenic dusts, fumes or where they may be working in un-ventilated or poorly ventilated areas. The correct selection and use of RPE is absolutely vital. For instance, the use of face masks is definitely not recommended against anything other than low concentrations of nuisance particulate matter or atomised liquids.

BS 4275 refers to the selection of RPE and lists Nominal Protection Factor (NPF) for different form of equipment. The NPF measures the theoretical capability of RPE and is calculated thus:

NPF=Concentration of contaminant in atmosphere / Concentration of contaminant in face piece

9.2.1 Face Masks

These are simple devices for holding filtering media against the nose and mouth to remove coarse nuisance dust particles or non-toxic paint sprays. They should not be used as a means of protection against hazardous or toxic substances.

9.2.2 General Purpose Dust Respirator

They take the form of an ori-nasal face mask which has a particulate filter to trap the finely divided solids or liquid particles.

9.2.3 Positive Pressure Powered Dust Respirator

These comprise an ori-nasal face mask fitted to a power-driven pack carried on individual and connected by a flexible hose. They are more effective than the simple form of dust respirator as they utilise a much more efficient filtering medium and operate with positive pressure in the face-piece.

a) Typical Half Mask Respirator, Typical Quarter Mask Respirator b) Detailed View of Heavy Cartridge Respirator and Dust Respirator c) Front and Back Mounted Canister Gas Mask

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.

9.2.4 Helmet-contained Positive Pressure Respirator

This form of device provides head, face, eyes and lung protection together with high degree of comfort. It incorporates a helmet and visor with high efficiency axial fan mounted on the rear of the helmet, which draws the dust laden air through a coarse filter. The partially filtered air is then passed through a fine filter bag. The filtered air provides a cool pleasant air stream over the entire facial area, and is finally exhaustedat bottom visor at a flow rate sufficient to prevent dust entering the mouth or nose. The low-voltage electric power is supplied by a light weight rechargeable battery pack, connected to the helmet by means of flexible cable. This portable battery pack may be clipped to a belt or carried in overall pocket.

9.2.5 Gas Respirator

The respirator takes the two forms; cartridge and canister. The cartridge respirator is similar to dust respirator. It uses a chemical cartridge filter and is effective against relatively low concentration of non-toxic gases or vapours which have an acceptable level of concentration exceeding 100ppm. Canister Respirators on the other hand are normally of full piece type, the exhaust valves, incorporating goggles and visor. They are connected to chemical filter for protecting against low concentrations of designated toxic gases or vapours. The manufacturer's instruction on avoidance of cartridge/canister saturation, maximum period of use in relation to gas concentration in air, shelf-life etc. must, in all cases be carefully followed. They are effective against toxic gases and vapours in limited concentrations. A particulate filter can be incorporated to remove dust particles.

1615

9.2.6 Emergency Escape Respirator

These are especially designed respirators using a chemical filter which will enable people to escape from dangerous atmospheres in an emergency. They are intended for very short term use and should never be used for normal protection.

9.2.7 Air-line Breathing Apparatus

This apparatus consists of a full mask or half mask connected by flexible hose either to a source of uncontaminated air (short distance) or to a compressed airline via a filter and demand valve. This apparatus is usually safe for use in any contaminated atmosphere but is limited to length of airline, which also places some restriction on movement. When using a fresh air hose a pump is necessary for lengths over 10 meters.

9.2.8 Self-Contained Breathing Apparatus (SCBA)

Limitation of the hose mask/ airline type breathing equipment is the trailing hose which may result in entanglement and the wearer must return by retracing his route in the contaminated atmosphere. The SCBA is self sufficient breathing equipment that permits freedom of movement as the wearer carries the supply of breathable air. The following three types are available:

1.Demand type compressed oxygen or Compressed Air Breathing Apparatus 2.Compressed Oxygen recirculation breathing apparatus 3.Oxygen generating type breathing apparatus

This device can be of the open or closed circuit type. The open circuit type supplies air by lung-governed demand valves or pressure reduces connected to a full face-piece via a hose supply. The hose is connected to its own compressed air or oxygen supply which is carried by wearer in his harness. The closed circuit type incorporates a purifier to absorb exhaled carbon dioxide. The purified air is fed back to respirator after mixing with pure oxygen. Both of these devices are used in dangerous atmospheres or where there is a deficiency of oxygen, or for rescue purposes from confined spaces.

Use air purifying apparatus only if the contaminant level in the air is less than 2% by volume. Use chemical cartridge only if contaminant level is less than 0.1%. Use canister only on knowing the colour codification, nature of contaminant and its shelf life. Use only for 02hrs. Maintain records for usage. Check for any physical damage before use e.g. punctures in hose, filter, etc.

9.3 Noteworthy point for Respiratory Protective Equipment

Use hose mask if pure atmosphere is within the reach of 20ft and the area is free from any hurdle or heat that has the potential to damage hose/air line. RPE shall be used with a standby person or helper present in the work area. Develop a system and implement effectively to ensure timely cleaning and disinfection of RPE. Follow the manufacturer recommendation for cleaning. The following procedures may also be followed:

-Remove all filters, cartridges, canisters, etc. -Scrub and clean the face piece components with soap and warm water to remove grease, a hand brush may be used if required. -Immerse the face piece in warm water for 05minutes and rinse it to clean. -Immerse the face piece in solution of Formalin (01 part of 40% of formaldehyde and 09 parts of water) or in solution of Sodium hypo chloride (01 parts of it in 09 parts of water) for 05 minutes. -Again rinse the face piece with cold water and air dry them in a clean place.

The use of PPE shall serve the purpose only when it is used with knowledge of its limitations. Especially the limitations of PPE must be known by the person who is going to use it. In any hazardous environment the use of PPE should be considered only as the last line of defence.

PPE does not help in anyway in removing or reducing the prevailing hazard conditions in environment; but it only provides limited and time bound protection. It is because of this reason PPE is not considered as a panacea for the hazards; it the last line of defence. The best way of ensuring full protection can only be achieved by eliminating the hazards by proper engineering and administrative control measures.

10. Limitations 0f personal protective equipment

Use of PPEs need care from risk angle so that persons wearing the PPEs should not be hurt during the use of PPEs.

One simple thumb rule will not be applicable for all types of the hazards and PPEs.

Proper hazards assessment and guidelines need to be followed, annexure 1 and 2 provides light in brief in general.

Annexure 3 provides in depth, as an example, what type of PPEs must be used during handling of acid.

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Appendix 1

The following steps must be followed on priority

Assessment date(s): Department: ........................................................................................................................................................ Building: .......................................................................................................................................................... Task or assignment description: ..................................................................................................................

Hazards identified: Eye and Face: ................................ Respiratory: .............................

Head: ............................. Foot: ..................................... Electrical: ............................... Hand: ........................................... Whole Body: ............................. Other: ..........................................

PPE requirements: Eye and Face: .................................................................. Respiratory: ............................................. Head: ........................................................................... Foot: ......................................................... Electrical: ................................................................... Hand: .......................................................... Whole Body: ..................................................................... Other: ..................................................... Other control measures: ................................................................................................................................. CERTIFICATION: I certify this hazard assessment was conducted in accordance with the provisions.

Name of certifying supervisor: Date:

Companies must do the hazards assessment and must recommend the PPEs

Certification of hazard assessment

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Appendix 2

Guidelines for hazard assessment and Personal Protective Equipment selection

I. Controlling HazardsPPE devices alone should not be relied on to provide protection against hazards, but should be used in conjunction with guards, engineering controls, and sound work practices.

II. Assessment and SelectionWhen assessing a task and selecting means of hazard control. It is the responsibility of the supervisor to exercise common sense and appropriate expertise to accomplish assessment and selection requirements. He should also refer the hazards identification report.

III. Assessment Guidelines

A. SurveyConduct a walk-through survey of the areas in question. The purpose of the survey is to identify sources of hazards to workers and co-workers. Consideration should be given to the basic hazardcategories: 1. Impact 2. Penetration 3. Compression (Roll-Over) 4. Chemical 5. Heat 6. Harmful dust 7. Light (Optical) Radiation

B. SourcesDuring the walk-through survey, the safety officer should observe: 1. Sources of motion; i.e. machinery or process where any movement of tools, machine elements or particles could exist, or movement of personnel that could result in collision with stationary objects; 2. Sources of high temperatures that could result in burns, eye injury of ignition of protective equipment, etc.; 3. Types of chemical exposures; 4. Sources of harmful dust; 5. Sources of light radiation, i.e. welding, brazing, cutting, furnaces, heat treating, high-intensity lights, etc.; 6. Sources of falling objects or potential for dropping objects;

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7. Sources of sharp objects which might pierce the feet or cut the hands; 8. Sources of rolling or pinching objects which could crush the feet; 9. Layout of workplace and location of co-workers; and 10. Any electrical hazards; in addition; injury/accident data should be reviewed to help identify problem areas.

C. Organise dataFollowing the walk-through survey, it is necessary to organise the data and information for use in the assessment of hazards. The objective is to prepare for an analysis of the hazards in the environment to enable proper selection of protective equipment.

D. Analyse dataHaving gathered and organised data on a workplace, an estimate of the potential for injuries should be made. Each of the basic hazards should be reviewed and a determination made as to type, level of risk, and seriousness of potential injury from each of the hazards found in the area. The possibility of exposure to several hazards simultaneously should be considered.

IV. Selection GuidelinesAfter Completion of the general procedure for selection of protective equipment is to:

A. Become familiar with the potential hazards and the type of protective equipment that is available, and what it can do, etc. i.e. splash protection, impact protection, etc.; B. Compare the hazards associated with the environment; i.e. impact velocities, masses projectile shape, radiation intensities, with the capabilities of the available protective equipment; C. Select the protective equipment which ensures a level of protection greater than the minimum required to protect the employee from the hazards; D. Fit the user with the protective device and give instructions on care and use of the PPE. E. Ensure that end users be made aware of all warning labels for and limitations of their PPE.

V. Fitting the DeviceCareful consideration must be given to comfort and fit. PPE that fits poorly may not afford the necessary protection. Continued wearing of the device is more likely if it fits the wearer comfortably. Protective devices are generally available in a variety of sizes. Care should be taken to ensure that the right size is selected.

VI. Devices with Adjustable FeaturesAdjustments should be made on an individual basis for a comfortable fit that will

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maintain the protective device in the proper position. Particular care should be taken in fitting devices for eye protection against dust and chemical splash to ensure that the devices are sealed to the face. In addition, proper fitting of helmets is important to ensure that it will not fall off during work operations. In some cases, a chin strap may be necessary to keep the helmet on an employee's head. (Chin straps should break at a reasonably low force, however, so as to prevent a strangulation hazard.) Where manufacturer's instructions are available, they should be followed carefully.

VII. Reassessment of hazardsIt is the responsibility of the supervisor to reassess the workplace hazard situation as necessary, by identifying and evaluating new equipment and processes, reviewing accident records, and reevaluating the suitability of previously selected PPE.

VIII. Selection guidelines for eye and face protectionSome occupations for which eye protection should be routinely considered are: carpenters, electricians, machinists, mechanics and repairers, millwrights, plumbers and pipe fitters, sheet metal workers and tinsmiths, assemblers, sanders, grinding machine operators, lathe and milling machine operators, sawyers, welders, laborers, chemical process operators and handlers, and timber cutting and logging workers. The appended chart provides general guidance for the proper selection of eye and face protection to protect against hazards associated with the listed hazard “source” operations.

IX. Selection guidelines for head protectionAll head protection is designed to provide protection from impact and penetration hazards caused by falling objects. Head protection is also available that provides protection from electric shock and burn. When selecting head protection, knowledge of potential electrical hazards is important.

Class A helmets, in addition to impact and penetration resistance; provide electrical protection from low-voltage conductors (they are proof-tested to 2,200 volts). Class B helmets, in addition to impact and penetration resistance; provide electrical protection from high-voltage conductors (they are proof-tested to 20,000 volts). Class C helmets provide impact and penetration resistance (they are usually made of aluminum which conducts electricity), and should not be used around electrical hazards.

Where falling object hazards are present, helmets must be worn. Some examples include: working around or under conveyor belts which are carrying parts or materials; working below machinery or processes which might cause material or object to fall; and working on exposed energized conductors. Some examples of occupations for which head protection should be routinely considered are: carpenters, electricians, linemen, mechanics and repairers, plumbers and pipe fitters, assemblers, packers, wrappers, sawyers, welders, laborers, freight handlers, timber cutting and logging workers, stock handlers, and warehouse laborers.

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X. Selection Guidelines for Foot ProtectionSafety shoes and boots which meet the Standard provide both impact and compressionprotection. Where necessary, safety shoes can be obtained which provide puncture protection. In some work situations, metatarsal protection should be provided, and in other special situations, electrical conductive or insulating safety shoes would be appropriate. Safety shoes or boots with impact protection would be required for carrying or handling materials such as packages, objects, parts or heavy tools, which could be dropped; and for other activities where objects might fall onto the feet. Safety shoes or boots with compression protection would be required for work activitiesinvolving skid trucks (manual material handling carts) around bulk rolls (such as paper rolls) and around heavy pipes, all of which could potentially roll over an employee's feet. Safety shoes or boots with puncture protection would be required where sharp objects such as nails, wire, tacks, screws, large staples, scrap metal, etc., could be stepped on by employees causing a foot injury.

Some occupations (not a complete list) for which foot protection should be routinely considered are: shipping and receiving clerks, stock clerks, carpenters, electricians, machinists, mechanics and repairers, plumbers and pipe fitters, structural metal workers, assemblers, drywall installers and lathers, packers, wrappers, craters, punch and stamping press operators, sawyers, welders, laborers, freight handlers, gardeners and groundskeepers, timber cutting and logging workers, stock handlers and warehouse laborers.

XI. Selection Guidelines for Hand ProtectionGloves are often relied upon to prevent cuts, abrasions, burns, and skin contact with chemicals that are capable of causing local or systemic effects following dermal exposure. It is important to select the most appropriate glove for a particular location and to determine how long it can be worn, and whether it can be reused. It is also important to know the performance characteristics of gloves relative to the specific hazard anticipated (e.g. chemical hazards, cut hazards like flame hazards, etc.) Their performance characteristics should be assessed by using standard test procedures. Before purchasing gloves, the employer should request documentation from the manufacturer that the gloves meet the appropriate test standard(s) for hazard(s) anticipated.

A. Other factors to be considered for glove selection in general include: 1. As long as the performance characteristics are acceptable in certain circumstances, it may be more cost-effective to regularly change cheaper gloves than to reuse more expensive types, and; 2. The work activities of the employee should be studied to determine the degree of dexterity required, the duration, frequency, and degree of exposure of the hazard, and the physical stress that will be required.

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B. With respect to selection of gloves for protection against chemical hazards: 1. The toxic properties of the chemical(s) must be determined; in particular, the ability of the chemical to cause local effects on the skin and/or pass through the skin and cause systemic effects; 2. Generally, any “chemical resistant” glove can be used for dry powders; 3. For mixtures and formulated products (unless specified test data are available), a glove should be selected on the basis of the chemical component with the shortest breakthrough time, since it is possible for solvents to carry active ingredients through polymeric materials; and, 4. Employees must be able to remove the gloves in such a manner as to prevent skin contamination.

XII. Cleaning and MaintenanceIt is important that all PPE be kept clean and properly maintained. Cleaning is particularly important for eye and face protection where dirty or fogged lenses could impair vision.

PPE should be inspected, cleaned, and maintained at regular intervals so that the PPE provides the requisite protection. It is also important to ensure that contaminated PPE which cannot be decontaminated is disposed of in a manner that protects employees from exposure to hazards.

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Appendix

Frequently asked questions on PPEs

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Q. What kind of PPE is used when loading/unloading acid?A. The recommended PPE for unloading/loading sulfuric acid is a hard hat, chemical goggles with a face shield, acid splash suit, rubber gloves and boots. The acid splash suit is typically a coated PVC material. An acid hood can be worn in place of the chemical goggles and face shield.

Q. Do you need respiratory protection for sulfuric acid?A. Respiratory protection is not required when handling non-fuming (<100%)sulfuric acid under normal conditions. Fuming sulfuric acid >100% (also known as oleum) may require an acid mist cartridge respirator or a supplied breathing source, based on the type of job and exposure monitoring results.

Q. Can you wear a face shield instead of chemical goggles?A. A face shield can be worn over the chemical goggles, but should never be worn in lieu of the goggles. With a face shield, acid can spray in from the side or from underneath the face shield - the eyes do not have "positive" coverage from a face shield.

Q. What do you wear in your plants?A. The type of Personal Protective Equipment (PPE) worn on our sites depends on the type of job and potential hazard associated with that job. For a plant walk-through, the minimum recommended PPE is a hard hat and chemical goggles. For low-hazard jobs, such as operating valves and pumps, the minimum recommended PPE is a hard hat, chemical goggles and acid resistant gauntlet-length gloves. For higher level potential hazard jobs, such as loading or unloading acid, a hard hat, chemical goggles, face shield, acid-resistant gauntlet-length gloves, acid resistant splash suit (not a rain coat) and acid-resistant boots, preferably steel-toed, are recommended. For 1st breaks into lines or other equipment that contained acid, the minimum PPE recommended is an acid-resistant hood, acid-resistant gauntlet-length gloves, acid- resistant splash suit and acid resistant-boots.

Q. From whom can I buy the acid gear?A. The acid gear can be purchased from a number of different suppliers. Make sure the suit material is truly acid-resistant for the % sulfuric acid you are handling on your plant site (i.e., make sure the suit is good for 93% acid, not just 20% acid, if you handle 93% on your site). Also make sure the suit is properly designed to minimize tears/rips at the arm-pits and crotch. Make sure the suit is properly sized. DuPont Protective Apparel markets several fabrics and styles of suits acceptable for sulfuric

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acid service.

Q. How far does a fume cloud of sulfuric acid go?A. Non-fuming sulfuric acid (<100%) has a very low vapor pressure and does not fume, so it will not have a fume cloud. If a spill occurs, sometimes people will notice an odour. This odour is usually the result of the sulfuric acid reacting with something (typically organic), or if the acid reacts with water and causes a splattering "mist."

Q. What are the main dangers associated with sulfuric acid?A. The main hazard associated with sulfuric acid is its corrosivity to skin and eyes. It can cause rapid damage to skin and eye tissue on contact, and may result in burns and/or permanent eye damage. Another potential with sulfuric acid is that if it is diluted it becomes much more corrosive to most metals. As the metals corrode, hydrogen gas is evolved. If the hydrogen gas collects (such as in a room or in a tank) it may reach the explosive range.

Q. Do I need to evacuate for an acid spill?A. The main hazard associated with an acid spill is contact with the liquid, which may result in burns to the skin and eyes. Evacuate an area large enough to prevent any liquid exposure to the acid. If the acid spill reacts with any other chemical/object on the ground and a resulting odor/mist is suspected, evacuate downwind.

Q. What do you use to neutralize/clean up a spill?A. In general any alkali will neutralize an acid spill. Soda ash, caustic soda, lime, limestone, and baking soda can be used. A "rule-of-thumb" is to dilute the acid to about 15% before trying to neutralize, if possible, to minimize the heat generated by the neutralization reaction. Once the pH has been adjusted to between 2-12, the spill waste can usually be treated as "non-hazardous waste". Verify this with your local and state regulatory agencies.

Q. What is your plant's Emergency Response Plan for an acid incident?A. The plant Emergency Response Plan is site-specific, based on the size of the plant, the number of trained responders typically at the plant at certain times, the availability of trained local community responders, etc. In general, for non-fuming sulfuric acid, the main consideration would be to contain the liquid, to keep it out of sewers, waterways and from the groundwater. The main safety hazard associated with non-fuming sulfuric acid is burns from skin/eye contact. The main environmental hazard is that it would quickly lower the pH of any water it reaches, causing potential damage to plants and wildlife.

Q. What kind of Emergency Response training do your plant people receive?A. All plant personnel receive the eight-hour OSHA HAZCOM 1910.119 "Right-to-Know"

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training. Every three years, plant operation personnel receive training that meets the 40-hr HazWoper training requirements. Plant personnel also participate in at least one drill per year involving sulfuric acid

Q. What is the first aid treatment for acid exposure?A. The first aid treatment for sulfuric acid is fairly simply - get as much water on the affected area, as fast as possible. Wash/rinse the affected skin area for at least 15 minutes. Follow-up the water wash by applying a clean, terrycloth soaked in ice-water. Continue to apply the ice-cold compresses until told to stop by a physician. The ice-cold compresses will "pull" the heat away from the burn area and minimize further damage to the skin tissue.

Q. Do burn gels work for acid exposures?A. No. Do not apply any burn gel to a sulfuric acid burn unless specifically told to do so by a physician.

Q. What kind (if any) training do you do with local hospitals/paramedics on acid burn treatment?A. The plants provide annual training/refresher training to the local hospitals/paramedics on the treatment of sulfuric acid exposures.

Q. Are drills recommended for potential acid spill/exposure incidents?A. Emergency response drills are highly recommended for potential sulfuric acid spills/exposures. We conduct quarterly drills with our four rotating shift personnel, so each shift participates in at least one drill per year.

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Exercise-1Please do the exercise for selecting PPEs while doing maintenance work of a

confined space vessel used for the storage of motor spirit and diesel.

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Exercise-3Do the risk assessment of SCBA, Footwear, Hand gloves, while using them in

emergency management of a area having dense smoke and fire

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Exercise-2Please do the exercise for selecting PPEs while doing maintenance work of a

vessel used for the storage liquid ammonia

Accident:

Active failure:

Barrier:

Hazard:

Human error:Human failure:Human-machine system:

Immediate cause (of an incident):

Incident:

Lapse:

Major accident hazard:

Occupational safety hazard:

any unplanned event that results in injury or ill-health to people, or damages equipments, property or materials but where there was a risk of harm.

a human error or violation the effects of which become evident almost immediately.

any measure taken to protect people or property from hazards, including physical guards but also administrative measures such as rules and procedures. Sometimes referred to as safeguards, defences or risk control systems.

anything with the potential for human injury or adverse health, damage to assets or environmental impact. See risk and risk assessment.

system failures attributable to people but not including violations. a term used to collectively refer to both errors and violations.

a system in which technology and human beings have specific functions but work together towards common goals.

the most obvious reason why the incident occurred e.g. The guard is missing, the employee slips etc. There may be several immediate causes identified in one adverse event.

an unplanned or uncontrolled event or sequence of events that has the potential to cause injury, ill-health or damage. Also referred to as a near miss.

when a person forgets to do something due to a failure of attention/concentration or memory.

hazards with the potential for major accident consequences, e.g. ship collisions, dropped objects, helicopter crashes as well as process safety hazards. Major accidents are potentially catastrophic and can result in multiple injuries and fatalities, as well as substantial economic, property, and environmental damage.

personal or occupational safety hazards give rise to incidents such as slips, falls, and vehicle accidents that primarily affect one individual worker for each occurrence(noting, of course, that they could affect many people). They contrast with process safety hazards and major accident hazards in that the latter have the potential to affect a very large number of people including those off-site.

11. Glossary

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1. Factories Act 1948.

2. Personal Protective Equipment, U.S. Department of Labor, Occupational Safety and Health Administration, OSHA 3151-12R, 2003.

3. Personal Protective Equipment at Work: Guidance on Regulations - ISBN 0-11-886334-7.

4. A short guide to the Personal Protective Equipment at Work Regulations 1992.

5. Indian Factories Act, 1948 and references therein.

12. References

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Notes

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Notes

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