Qual all wrk 043 chemical management book

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SUPPLIER CHEMICALMANAGEMENT BOOK

QUAL ALL WRK043 CHEMICAL MANAGEMENT BOOK VA

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created by Qual i ty Di rect ion - Indust r ia l Div is ion of Oxy lane - Conf ident ia l - March 2010 created by Qual i ty Di rect ion - Indust r ia l Div is ion of Oxy lane - Conf ident ia l -March 20102


created by Qual i ty Di rect ion - Indust r ia l Div is ion of Oxy lane - Conf ident ia l -March 2010

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This booklet has been given to you by a company from the OXYLANE. It is a confidential document, and remains the exclusive property of the OXYLANE. It may not be forwarded or used by third parties without prior agreement from us. This booklet is not a contractual document, but a collection of information about the chemical risk management in a production site.

These requirements are general, independent of any specific industrial or economic sector. They can be used as a reference base to help you assess where improvements or corrective action is required.

INTRODUCTION


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P05 - Part 01 : Identification P06 - What is a chemical ? P07 - How to identify it ?

P09 - Part 02 : Hazards P10 - Ways of exposure P11 - Corrosive material P13 - Toxic & Noxious material P16 - Fire / Explosion P19 - Part 03 : Emergency : Procedures & Equipment P20 - First Aid P21 - Spillage P21 - Fire

P23 - Part 04 : Storage & Transportation P24 - Risk P24 - Safe Transportation P25 - Storage Guidelines P28 - Hazardous Waste

P31 - Part 05 : Chemical Risk Analysis P32 - Responsibility P32 - Inventory P32 - Risk Analysis P36 - Action Plan

P37 - Part 06 : Prevention P38 - Prevention Plan P38 - Elimination & Substitution P39 - Collective Protection P43 - Individual Protection

P47 - Part 07 : Auditing P48 - Exposure Follow-up P49 - Audit Grid - Examples P51 - Tools

P53 - Part 08 : Appendix P54 - Sources P54 - International Guidelines P55 - Training Material P55 - Information on Chemicals

SUMMARY

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Know how to evaluate the chemicals management of a supplier.

To protect the health of the workersin production and prevent accidents.

PL Tech, Quality Managers, Buyers, Supplier health & Safety Managers...Anyone in contact with chemicals.

OBJECTIVE ?

WHY ?

WHO ?

INTRODUCTION


Part 01 - IDENTIFICATION Par t 02 - HAZARDSPar t 03 - EMERGENCYPar t 04 - STORAGE & TRANSPORTATIONPar t 05 - CHEMICAL R ISK ANALYSISPar t 06 - PREVENTIONPar t 07 - AUDITINGPar t 08 - APPENDIX

IDENTIFICATIONWhat is a chemical ?

How to ident i fy i t ?

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What is a chemical ?

Every gas, liquid or solid used in the process, exept water and comprened oil.- A chemical substance can be found pure or in a diluted form or mixed into a preparation.

Examples :acids, dyes, solvents, cleaning agents, detergents, adhesives, drying agents, paints,oils …

At home too! In your garage, kitchen, bathroom…- pesticides, bleach, disinfectant, oil, antiscale…

DUST GAS VAPOUR

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How to identify a chemical ?

1. Product Label

Label Pictograms EquivalenceEuropean and International Classifications

Product’s Name

List of healtth or physical hazards

Storage and handling precautions

Hazard warning

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• Latest update should be less than 3 years old

• Product identification : - Trade name - Supplier contact

• Identification of hazardous components : - Name - CAS number : only way to identify precisely the chemical (1 chemical substance can have different name but only 1 CAS number).All existing chemicals have a CAS number.

• Physical and chemical properties

• Exposure limits (limit allowed in the air)

• Fire and explosion data : - Flash point - Auto-ignition temperature - Explosive limits - Fire fighting means and conditions.

• Health hazards (including signs and symptoms of overexposures)

• Precautions for safe use: handling, storage and disposal

• Protective equipment

• Emergency and first aid procedures

“MSDSs” are information sheets on products that :

- Tells what hazardous chemicals are present in the product- What the hazards of the chemicals are- How to protect yourself from the hazards

Are provided for free, in the local language, by the chmicals supplier (mandatory)

Give very brief information on products : (cf. p 42/56) - Name - Hazards - Protective measures, including PPE - First aid procedure - Safe disposal

Based on MSDSWritten by the Safety Manager of the factory.

Easily understandable.Posted everywhere the chemical is used and stored

4. chemical sheet

2. Material safety data sheet (MSDS)

3. MSDSs – Key information


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02HAZARDS

Ways of exposureCorros ive mater ia l

Tox ic & Noxious mater ia lF i re / Explos ion

Par t 01 - IDENTIF ICATION Part 02 - HAZARDSPar t 03 - EMERGENCYPar t 04 - STORAGE & TRANSPORTATIONPar t 05 - CHEMICAL R ISK ANALYSISPar t 06 - PREVENTIONPar t 07 - AUDITINGPar t 08 - APPENDIX

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• Chemicals on dirty hands can contaminate food, drinks or tobacco products.

• Chemicals in the air can settle on food or drink and be swallowed.

• Vapor and dust are breathed in through the mouth or nose.

How chemicals enter the body ?

1. Ingestion (Swallowing)

2. Inhalation (Breathing)

3. Skin Absorption


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• No food, drink (or food and drink containers) in the workshop.

• Wash your hands before eating and drinking.

• Wash your hands before and after going to the bathroom.

• Do not wear contaminated clothes outside the workplace. - Change clothes at the end of your shift. - Do not take them back home

• Keep the workplace clean.

4. Hygiene rules

Corrosive

1. Definition

• Bases : caustic soda, ammoniac…• Acids : hydrofluoric, sulfuric, acetic…

- Violent reactions with water - Can form explosive mixture or release toxic gas in contact with other chemicals - Cause severe burns

• Oxidizing material: bleach, peroxides…

- Can form explosive mixture or release toxic gas when in contact with other chemicals

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BURNS !

• Corrosion - Perforation - Leakage

2. Effects on human health

3. Effects on equipement


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• Pollution - Burns plants and animals - Irritations for exposed populations

TOXIC : •Capable of causing injury or death. - Chlorinated solvents, Dimethylformamide (DMF), Isophorone…

CARCINOGEN/MUTAGEN/ toxic for Reproduction : • Capable of causing cancer, birth defects, affect fertility. - benzene, n-Hexane, methylene chloride, chlorobenzene, DMF...

THIS CHEMCALS SHOULD BE REPLACED AS SOON AS POSSIBLE IN PRODUCTION

NOXIOUS : • injurious to health. - Toluene, xylene, cyclohexane, neoprene glue…

SENSITILER/IRRITANT : • Capable of causing inflammations, irritations to the skin, eyes and respiratory system. - Methyl ethyl ketone (MEK), isopropyl alcohol, methyl methacrylate (MMA)....

4. Effect on the environment

Toxic & Noxious

1. Definition

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ACUTE INTOXICATION : • Massive dose, quick clinical signs. - may cause nausea, headaches, dizziness, breathing difficulties. Ex: if you stay a few minutes in a room full of paint and not ventilated, you feel dizzy or your head aches. You feel better when you breath fresh air again. - may be fatal or cause permanent damage if inhaled or swallowed, or up on entering the body through skin contact.

LONG TERM INTOXICATION : • Repeated small dose, irreversible diseases. • Symptoms appearance can take a long time. - may cause permanent damage as a result of repeated exposures over time: allergies, cancer, birth defects or sterility. Ex: if you paint without appropriate protection everyday during 10 or 20 years, you can develop a cancer. Ex: if you use toxic glue everyday during your pregnancy, you can loose your baby.

A chemical can cause both acute and long term intoxications

2. Effects on human health

POISONS !


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Chemicals are transferred by a pregnant woman to her baby. - Potential consequences : Spontaneous abortions, birth defects.

Chemicals are transferred to the baby by the mother’s milk. - Potential consequences: development disorders…

Example of chemicals leading to these effects :- Surface treatment: lead, cadmium, chromium…- Solvents: N-hexane, DMF (Dimethylformamide), glycol ethers (Cellosolve, ethylene glycol…), Tetrachlorethylene…

3. Pregant & nursing women


5. Effect on the environment

• Pollution - Contamination

• Pollution of air, soil, water

• Toxic for plants and animals : - Accumulate in the food chain - Alter reproduction - Affect biodiversity • Toxic for exposed populations

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fire, explosions, heat generation, noxious gas generation, Spitting of harmful substances

Flammable and Combustible Material• May light and cause a fire when exposed to heat, sparks, flames or as a result of friction. = FUEL Ex: acetone, MEK…

Oxidizing Material contribute to the combustion of other material.• May react violently or cause an explosion when contacting combustible ma-terials. = OXIDIZING AGENT Ex: peroxydes, oxygen…

Compressed Gases• Explosive danger (gases under pressure); may cause container to explode if heated in a fire or subjected to impact forces. Ex: all gas in containers.

Dangerously Reactive Material• may explode as a result of shock, friction or increase in temperature; may explode if heated in a closed container. Ex: ammonium perchlorate, perchloric acid solutions…

Fire & Explosion

1. Physical and chemical hazards

2. Chemicals that can lead to these effects

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3. Fire Triangle

4. Definitions

• In order to ignite and burn, a fire requires three elements : - heat, fuel, and an oxidizing agent, usually oxygen.

• Ignition source: A device or item that is capable of generating sparks or enough heat to pro-duce combustion. (electric spark, open flame, cigarette, hot surface…)

• Flash point : lowest temperature at which sufficient vapors form above a liquid to catch fire when an ignition source is present.

• Auto-Ignition point : temperature at which, in the presence of sufficient oxygen, a material will ignite on its own and burn (spontaneous ignition).

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• All potential heat source :- thermal, electric, electrostatic, mechanical, climatic… Ex.: hot surfaces, sparks, flames…

• Contamination by toxic fumes and gas• Destruction

• Air pollution by toxic fumes and gas• Emission of greenhouse gas (global warming)

5. Possible Ignition Causes


7. Effects on the environment


EMERGENCYPROCEDURES AND EQUIPMENT

F i rs t A idSpi l lage

Fi re

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Par t 01 - IDENTIF ICATION Par t 02 - HAZARDS Part 03 - EMERGENCYPar t 04 - STORAGE & TRANSPORTATIONPar t 05 - CHEMICAL R ISK ANALYSISPar t 06 - PREVENTIONPar t 07 - AUDITINGPar t 08 - APPENDIX

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• Skin /eye contact / burn :- Wash thoroughly with RUNNING water for 15 minutes.- Take off the contaminated clothes under the shower.

• Inhalation :- Remove to fresh air.

• Ingestion : - do not drink - rinse the mouth with water - do not swallow the water - do not force to vomit

• Eye wash station• Safety shower

Clean and well maintained Sufficient water supply (for 15 minutes) Cleaning water collected and treated

FIRST AID

1. First Aid Procedure

2. First Aid Equipment


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• Give the alert• Wear protections• Stop the spreading• Confine the area• If the chemical is a solid : avoid dust production during the cleaning

• Absorbents : • Barriers- granules - sand- pillows- mat

SPILLAGE

FIRE

1.Spillage / Emergency Procedure

1. FIRE / Emergency Procedure

2.Spillage / Emergency Equipment

• Give the alert / sound the alarm: - Give precise information : Where is the fire? What is burning? What is being done?

• Check that nobody is in the fire area.• If the fire is still manageable : - Take the closest appropriate extinguisher (NO WATER!!!) - Direct stream at the base of the flames• Confine the area: close doors and windows.• Evacuate the building : - By the nearer emergency exit - Go to the meeting point - Wait for direction from the management / firemen.

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2. FIRE / Emergency Equipment

Foam Water CO2 DryPowder

Paper / Wood / carboards / Textile OK OK OK

Flammable liquids chemicalspetrol, solvent, oil, fats, greases...

OK OK OK

Flammable gaspropane, butane,natural gas...

OK

Electrical fires involving electrical equipment

OK

Extinguishers should be accessible and checked regularly

• EXTINGUISHERS

• FIRE BLANKETS


STORAGE& TRANSPORTATION

RiskSafe Transpor tat ionStorage Guidel ines

Hazardous Waste

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Par t 01 - IDENTIF ICATION Par t 02 - HAZARDSPar t 03 - EMERGENCY Part 04 - STORAGE & TRANSPORTATIONPar t 05 - CHEMICAL R ISK ANALYSISPar t 06 - PREVENTIONPar t 07 - AUDITINGPar t 08 - APPENDIX

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• Containers must be labeled, closed and in good condition.

• Containers materials must be compatible with the content.

• Avoid leaks, spillage and mistakes : - NO GLASS in workshop (unbreakable containers) - NO METAL for corrosives (acids, bases, oxidizers) - NO FOOD PACKAGING.

• CONTAINERS MOVERS

• CHAINED CYLINDERS AND DRUMS + Written procedures on loading and unloading hazardous material. + Inform the transporters on the hazards of the shipped material.

STORAGE RISK

SAFE TRANSPORTATION CONTAINERS


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1. Storage Guidelines

COMPATIBILITY

STORAGE GUIDELINES

• Chemicals stored by hazards category.Check MSDS for pH and compatibility : - Separate acids and bases - Separate flammables and toxics - Separate oxidizing materials and flammables - Separate compressed gases and flammables

• List of stored chemicals up-to-date : - See MSDS for hazards and incompatibilities, - Mention possible reactions, - Available in the storage room.

Damaged, out-of-date and unused chemicals should be eliminated ASAP(see chemical waste).

NOT OK OK under condition(see msds)

OK

Cheminal name Quantity Hazard Incompatibility Reactions

Transprene 113 M 10*50 L Flammable Nitric acid Toxic vapors

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• Storage room : - Separated area, - Locked, access limited to authorized personnel only, - Electrical installations protected against explosion (no sparks), - Sheltered (protection against sunlight and rain), - Well ventilated, appropriate temperature maintained, - Hazards identified (warning signs clearly visible, chemical sheets available), - Secondary containment for hazardous liquids, - Fire extinguishers, - Water supply within 10s for eye and body cleaning, - Spill response kit available.

• Containers / Big bags : - Closed, - Durably and legibly labeled in a language spoken by workers, - In good condition (no holes or leaks).

• Hazardous liquids on retention tanks.

• Heavy containers close to the ground. - Do not pile up containers!

• Collection drain or retention rim around chemical storage.

• Retention tanks: - Material compatible with the stored chemicals. - Volume equivalent to the largest volume either :

Largest volume of the containers stored on tank OR

2. Hazardous Liquids Retention

€

volumes∑2


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3. Retention Example

4. Compressed Gas Storage

• WARNING Keep compressed gas away from heat and sun.

€

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VMAX =100L

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• Hazardous waste includes : - spent chemicals, pesticides, - used oils, batteries, electrical equipment, - contaminated clothes and materials, - empty chemical containers…

• To respect the environment and national regulations: - do not mix hazardous waste with regular waste, even in small quantities. - do not throw up any chemical in the sink or sewer system. - eliminate hazardous waste as soon as possible.

• Should be collected separately : - Specific and identified containers in the waste production area: - Use different containers for hazardous waste. - Do not mix with regular waste.

- Storage in assigned areas : - Hazardous waste collected in the workshops should be stored as hazardous chemicals, in a specific building outside the production building.

• Should be handled and stored with the same precautions than hazardous chemicals.

- Proper containers : - Compatible with their content (no metal for acid or caustic waste to avoid corrosion),

- Closed and in good condition, - Labeled with « hazardous waste », name of the waste, warning signs. - Stored in assigned areas: - With secondary containment, - Sheltered, - Locked, - Visible warning signs (WARNING – HAZARDOUS WASTE), - Properly ventilated.

HAZARDOUS WASTE


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• Should be disposed of by a qualified contractor to be recycled, treated, incinerated or buried in a hazardous waste landfill.

• UNPROPER STORAGE

NOT OK !

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CHEMICALRISK ANALYSIS

Responsib i l i tyInventory

Risk Analys isAct ion Plan

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Par t 01 - IDENTIF ICATION Par t 02 - HAZARDSPar t 03 - EMERGENCYPar t 04 - STORAGE & TRANSPORTATION Part 05 - CHEMICAL RISK ANALYSISPar t 06 - PREVENTIONPar t 07 - AUDITINGPar t 08 - APPENDIX

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SIS • Appoint a chemical products responsible.

- Either the health & safety manager. - Or someone with good knowledge on chemicals.

• will follow all matters concerning chemicals.( purchasing, storage, handling, waste management )

• The Chemical products responsible must: - Identify the hazards - Estimate exposure - Know the country regulation - Set the appropriate organization : prevention means and emergency procedures.

Compile in a table all the below information for each chemical used in the factory:

• What ? - Name, chemical family, aspect, hazard , incompatibilities.• Where ? - Storage location, place of use.• How much ? - Quantity in store, quantity used per year.• Why ? - Use. • When ? - Utilization frequency. • How ? - Handling.• Who ? - Users.

• For each risk :

HEALTH

FIRE

ENVIRONMENT

• For each chemical identified in the inventory: - rating the quantity used and frequency of use gives the potential exposure. - After rating the hazards, it is possible to estimate the risk potential. - This estimation gives the priorities of action.

CHEMICAL MANAGEMENT RESPONSIBILITY

1ST step : INVENTORY

2ND step : CHEMICAL RISK ANALYSIS

1. Risk Assesment


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Chemicals

EQUIPEMENTSOPERATING PROCEDUREOPERATOR

TYPE, QUANTITIES (Hazards)

OPERATING CONDITIONS (Exposure)

RISK

2.Quantity Used

3.Utilisation Frequency

Quantity Class Q product/ Q total chemicals

1 <1%

2 1 to 5%

3 5 to 12%

4 12 to 33%

5 > 33%

Use Occassional Periodic frequent permanent

Day < 30 min 30 to 120 min 2 to 6h > 6h

Week < 2 hours 2 to 8 h 1 to 3 days > 3 days

Month < 1 day 1 to 6 days 6 to 15 days > 15 days

Year < 15 days15 days to 2

months2 to 5 months > 5 months

FrenquencyClass 1 2 3 4

0 if the chemical has not been used in more than a year

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4. Potential Exposure

5. Hazard Rating (example)

QuantityClass

ExposureClass

5 0 4 5 5 5

4 0 3 4 4 5

3 0 3 3 3 4

2 0 2 2 2 2

1 0 1 1 1 1

0 1 2 3 4 FrequencyClass

HazardsClass 1 2 3 4 5

Flash Point> 100°C

FP > 70°C FP > 40°c FP > 20°C FP <20°C

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6.Risk potential (example)

7.Categorization

Exposure

5 100 1000 10000 100000 1000000

4 30 300 3000 30000 300000

3 10 100 1000 10000 100000

2 3 30 300 3000 30000

1 1 10 100 1000 10000

1 2 3 4 5 Hazard

Score by product Priority of action

> 10000 HIGH

100 to 10000 AVERAGE

< 100 LOW

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1- REDUCE EXPOSURE (substitute, modify the process and equipment, minimize the number of person exposed) 2- COLLECTIVE PROTECTIONS (information, ventilation, …) 3- INDIVIDUAL PROTECTIONS

• Control measures, from the most effective to the least preferable :

1- Elimination / substitution for a less hazardous or volatile chemical; 2- Collective protection - isolation - engineering controls (ventilation, pumps, chemicals delivery) - administrative controls and work practices (information, training) 3- Personal protective equipment.

All strategies are not always applicable. more than one type of strategy may be needed for best exposure protection.

3rd STEP : ACTION PLAN


PREVENTION

Prevent ion PlanEl iminat ion & Subst i tut ion

Col lect ive Protect ionIndiv idual Protect ion

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Par t 01 - IDENTIF ICATION Par t 02 - HAZARDSPar t 03 - EMERGENCYPar t 04 - STORAGE & TRANSPORTATIONPar t 05 - CHEMICAL R ISK ANALYSIS Part 06 - PREVENTIONPar t 07 - AUDITINGPar t 08 - APPENDIX

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• Control measures, from the most effective to the least preferable :

1- Elimination / substitution for a less hazardous or volatile chemical; 2- Collective protection - isolation; - engineering controls (ventilation, pumps, chemicals delivery); - administrative controls and work practices (information, training); 3- Personal protective equipment. All strategies are not always applicable. more than one type of strategy may be needed for the best exposure protection.

• Whenever possible, avoid using chemicals : - Ex. : Cleaning with water and soap instead of solvents.

• Replace all toxic and CMR chemicals(Carcinogen, Mutagen or toxic for Reproduction) by less hazardous chemicals. - Eliminate benzene, chlorinated solvents, DMF.

• Whenever possible, replace volatile chemicals by less hazardous and volatile ones.

PREVENTION PLAN

ELIMINATION & SUBSTITUTION


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• Avoid human handling. - Automated processes.

• Limit exposure. - Limited quantities of chemicals in the workshop, - Closed containers, - Ventilation, - Work practices.

• Inform on hazards. - Posting, - Labels, - Chemical sheet, - Training.

• AUTOMATED DISPENSERS

COLLECTIVE PROTECTION

1. Avoid Human Handling

2. Exposure Limitations

• Limited amounts of chemicals in the workshop: - quantity needed for the day / shift only.

• Closed containers: - Avoid formation of dust and vapor.

• Effective ventilation: - Limit the workers exposure to chemicals in the air.

• Good work practices

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• Ventilation system equipped with air filters to remove particles(mechanical, electrical) and gases and vapors (activated charcoal).

• Ventilation system well maintained and cleaned, filter regularly changed. • Contaminated air flow directed away from fresh air supply. for exhausted fumes not to be drawn back into the building (heating, air conditioning vent, fans, …).

Where will the gas / fumes / vapors go? => Check MSDS to know the Vapor Density.VD of air is 1 => check if the gas is heavier or lighter than air.

Most solvents are heavier than air ! => choose a lower exhaust

VENTILATION GUIDELINES :

• Principle : exhausting contaminated air away from the work area and replacing it with clean air. It is one alternative to control employee exposure to air contaminants in the workplace.

• The design and troubleshooting of industrial ventilation systems should be handled by a qua-lified ventilation engineer or firms specializing in this field.

• Ventilation equipment posted as close as possible from emission point. - Air flow directed away from the workers. - Air flow adapted to emissions


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WORK PRACTICES :

- Rules defined and communicated by the safety manager of the factory.

Including but not only : - Mandatory use of PPE when necessary. - Restricted access to the chemicals storage room. - Handling of chemicals authorized for trained personal only. - No handling of chemicals by pregnant or nursing women.

• Chemicals are transferred by a pregnant woman to her baby. Potential consequences : Spontaneous abortions, birth defects.

• Chemicals are transferred to the baby by the mother’s milk. Potential consequences : development disorders…

• Example of chemicals leading to these effects : - Surface treatment : lead, cadmium, chromium - Solvents : N-hexane, DMF (Dimethylformamide), glycol ethers (Cellosolve, ethylene glycol…), Tetrachlorethylene…

• VENTILATION example

3. Pregnant & Nursing Women

NO FANS : Fans spread the emissions in all the workshop and contaminate allthe workers !

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LABELS• Information duplicated on all the sub-containers : - Pictograms - Name of the product - Handling precautions (except on very small container)

POSTINGS

4. Hazards Information

• Employees have the right to know the properties and potential safety and health hazards of substances to which they may be exposed.

• Information must be readily available.

• Chemicals must be easy to identify.

• Employees must be trained.


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• Written by the Safety Manager, based on MSDS.• Easily understandable.• Posted everywhere the chemical is used and stored.

• Before they start working with chemicals, workers must know and understand :

- How to read the chemical safety information (labels, pictograms, chemical sheets), - The hazards of the products they work with, - The safe ways of handling those products for them and others, - The safe storage rules, - The PPE they should use, - The hygiene rules, - How to dispose of the product, - The emergency procedures.

work permit (renewable every year) for workers in contact with chemicals. Written records of the training sessions.

• Personal protective equipment must only be considered as a hazard control measure after all administrative controls (Substitution of the most hazardous chemicals, limitation of the number of workers exposed to chemicals, …)

and practical engineering controls (ventilation, automated process and dispensers…)

INDIVIDUAL PROTECTION

1.Personal Protective Equipment (PPE)

MEKHazards

Vapors highly flammable.Irritating by skin or eye contact and by inhalation. Harmful if swallowed.

Safe Use

Use butyl gloves, use goggles or glasses.Keep away from heat, sparks and flames. Work only with fresh air supply.

First Aid

After eye contact: Rinse for 15 minutes with water.After skin contact: Take of soiled clothes. Wash with soap and water. Rinse for 15 minutes with water.

Disposal

Do not pour into sewage or regular bin.Collect in labeled container.

CHEMICAL SHEET EXAMPLE

Hazards Information : TRAINING

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• Google, spectacles: protect the eyes against spatters of toxic, noxious and corrosive material.

• Face shields: protect the face against spatters of corrosive materials. - Not efficient against dust or toxic and noxious vapors.

Should be kept clean and changed when contaminated

3.PPE : Face & Eyes Protection

• Do not breath vapors and dust• Avoid any contact with the eyes and the skin Wear personal protective equipment (PPE)

2.PPE : Individual Protections for Chemicals

have been used and it still remains a need for additional protection.

- PPE must be supplied to workers who do potentially hazardous work.- Managers must require that PPE be worn. - Workers must be trained to use this equipment properly.- Workers must be informed about the health and safety risks of not wearing the required PPE.- PPE must be appropriate and tested to make sure it fits the worker.


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• Masks: protect the throat and lungs against dust and vapors. Appropriate filtration chosen by the safety manager :

• Solvents and toxic dust and mist: filter mask. - Filter changed at least once a week. - Filter hermetically closed when not used. - Mask stored in a non polluted atmosphere.

Filter Codes : written on the filter. P = Particulates, e.g. dusts, mists (spray), metal fumes. A = Organic gases/vapors above 65°C. B = Inorganic gases. E = Acid gases. K = Ammonia. AX = Organic gases/vapors below 65°C. Hg = Mercury.

SL = Solid and Liquid (oil based) particulates.

• No Hazardous dust and mist (spray) : Disposable mask. - Choose masks providing a good face seal - Change mask at each shift (at least every day).

4. PPE : Respiratory Protections

5. PPE : Hands Protections

• No knitted gloves (cotton, polyester, nylon, wool…) - Only plastic or rubber gloves chosen by the safety manager according to the che-micals used.

Chemicals Latex Nitrile Neoprene PVC PVA Btuyl Teflon/Viton Multilayered

Carboxylic acids(acetic…)

X X X X

Aldehydes, Esters(Ethyl or butyl acetate…)

X X X

Primary alcohols(isopropyl alcohol…)

X X X X

Ketones(Acetone, MEK, cyclohexanone…)

X X

Aliphatic hydrocarbons(n-hexane, cyclohexane...)

X X X

Aromatic hydrocarbons(toluene, xylene, naphta…)

X X X

Chlorinated hydrocarbons X X X

Aqueous solutions(soda, chlorhydric or sulfuric acid…)

X X X X X X X

Disposable gloves = NOT RE USABLE !

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• Workers handling chemical must : - wear the protective clothes and shoes chosen by the safety manager. - change at the end of the shift and before meals. - must not take contaminated clothes and shoes at home (to protect their home and the health of their family!)

6. PPE : Body & Feet Protection

CHEMICALS ARE DANGEROUS : WEAR PPE !

- COMMON CHEMICALS IN PRODUCTION


AUDITING

Exposure Fol low-upAudi t Gr id - Examples

Tools

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Par t 01 - IDENTIF ICATION Par t 02 - HAZARDSPar t 03 - EMERGENCYPar t 04 - STORAGE & TRANSPORTATIONPar t 05 - CHEMICAL R ISK ANALYSISPar t 06 - PREVENTION Part 07 - AUDITINGPar t 08 - APPENDIX

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• The concentration of chemicals in the air should be kept underThreshold Limit Value (TLV) or Permissible Exposure Limit (PEL).

= level of exposure of the typical worker without risk of disease or injury. - can be found on the MSDS. - must respect the local regulation.

These limits can be expressed in 2 different ways : - Ceiling values (C) : at no time should this exposure limit be exceeded. - 8-hour Time Weighted Average (TWA) : average value of exposure over the course of an 8 hour work shift.

• For each worker in contact with chemicals:

- Exposure sheets with : name of the chemical, collective and personal protection, level, duration and frequency of exposure. - Annual medical check-up reports. - Record of accidents, sick leave and occupational disease.

! Collective protection is always required ! (whatever the chemical concentration in the air)

• Then, exposure measurement (8h Time Weighted Average and Ceiling value) should be performed to check the efficiency of the collective protection.

HOW ? - Gas detector with pump to simulate the breathing.WHERE ? - At the most exposed post. Captor at breathing level.WHEN ? - At least once a year.

EXPOSURE FOLLOW-UP

1. Limitations

2. Measurement

3. Medical Follow-Up


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• 3.4 Global risk analysis: (See hazard rating) - Chemical risk analysis : Available? Complete? Relevant? Update frequency? - Effectively implemented in the factory?

• 3.5 At the sickbay, check: - Availability of MSDS? - Register for frequency and gravity of : > accidents due to chemicals (including benign ones), > professional diseases. - register of actions taken after accident ?

• 3.7 Emergency procedures: - adapted to chemicals : first aid, spillage, fire? - known and communicated? - emergency material available ?

• 3.8 Training: - record of the training sessions? - workers handling chemicals have been properly trained?

• 3.9 Are pregnant women : - handling chemicals? - exposed to solvents (in the workshop, production lines…)?

• 3.12 Ventilation: - Are all chemicals storage or handling areas efficiently ventilated ? - How often is the chemicals concentration in the air controlled ?

• 3.13 Check cleanliness of chemical storage and workshops: - are chemical containers clean and closed? - are machines and equipment contaminated by chemicals?

• 3.18 Workplace safety: - are transportation means available and adapted for chemicals? - Is there any risk of chemical spilling?

• 3.23 Neither food/drink nor food/drinks containers in workshops or chemical storage room.

AUDIT GRID : WHAT TO CHECK ?

NOT OK !

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• 3.28 Workshop ventilation: (See ventilation guidelines) - do workers handling chemicals work with proper ventilation at their work station? - is the air flow directed away from the workers? - is the ventilation system regularly and properly maintained?

• 3.29 Chemicals storage room: (See storage guidelines) - is chemical storage separated from the workshop? - is it sheltered? - is it locked and accessible to authorized personnel only?

• 3.30 Chemicals storage ventilation: (See ventilation guidelines) - is the ventilation exhaust directed away from the workshop and any air intake? - is the temperature well controlled?

• 3.31 Incompatible chemicals: (See labels and compatibility table) - Are all containers properly labeled? - Are incompatible chemicals properly separated? - Are liquid chemicals placed on empty and clean retention tanks?

• 3.32 Chemicals containers: (See labels and containers guidelines) - Are containers materials adapted (no glass, no food containers)? - Are containers materials corroded? closed? - Are containers materials legibly labeled, in the workers language?

• 3.33 Workers handling chemicals: (See training and PPE) - Are they aware of the hazards of the chemicals they use? - Do they know how to protect themselves and others? - Are they wearing the adapted PPE? - Do they know what to do in case of emergency?

• 3.34 Information on chemicals: (See hazards information) - Are MSDS available for all chemicals? Complete? Up-to-date? - Are chemicals safety data sheets clear and up to date? - Are CSDS available next to the chemicals (workshop and storage)? - Are CSDS known and understood?

• 3.35 Emergency means: (See emergency guidelines) - Are they reachable easily and easy to find? - Do safety showers and eye wash have water supply for 15 minutes? - Are the fire fighting means adapted to chemicals (no water)? - Are spill response kits available? - Do workers know how to use them?

• 3.36 Personal protective equipment: (See PPE) - Are PPE adapted to the chemicals (no dust mask for solvent, no textile gloves…)? - Are PPE regularly cleaned and changed (at every shift for disposable gloves and masks, filters changed every week on masks…)? - Are PPE available everywhere chemicals are used or stored?

• 3.37 Workers and PPE: (See PPE) - Do workers handling chemicals wear the PPE mentioned on MSDS (protective clothes, protective shoes, goggles, gloves, masks…)? - Are PPE properly and regularly worn by workers? - If not, check why: - not available? bad training? wrong size? too heavy?...


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• 3.38 Posting: (See hazards information) - Is there a posting on hazards, PPE and emergency procedures? - Is it clearly visible? - Is it understood by all workers?

• 3.55 Fire prevention: - Are flammable chemicals handled and stored away from any heat source? - Are flammable chemicals stored away from any oxygen source? - Are chemical wastes safely and regularly disposed of?

AUDIT TOOLS

• Portable smoke generator. - Air current detection: - Ventilation systems check - Smoke detectors check - Leaks detection

• Flow meter. - Air flow measurement - Ventilation systems check

• Test tubes. - Gas concentration measurements - Exposure limit check

NOT OK !

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• DRÄGER SAFETY- www.draeger.com

• 3M- solutions.3m.com

• SPERIAN (ex-BACOU DALLOZ)- www.sperianprotection.com

• MSA- www.msanet.com

• Every factory is different,• Every process is different.

Each solution should be adapted to the situation.

1. Audit tools and PPE International Suppliers

2. Use Common Sense !


APPENDIX

SourcesInternat ional Guidel ines

Tra in ing Mater ia l Informat ion on Chemicals

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Par t 01 - IDENTIF ICATION Par t 02 - HAZARDSPar t 03 - EMERGENCYPar t 04 - STORAGE & TRANSPORTATIONPar t 05 - CHEMICAL R ISK ANALYSISPar t 06 - PREVENTIONPar t 07 - AUDITING Part 08 - APPENDIX

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• INRS: French only - http://www.inrs.fr/

• Material and equipments pictures: - French - http://www.manutan.fr/ - English - http://www.keyonline.co.uk/

• International Labour Organisation : EnglishC170 Chemicals Convention, 1990: - http://www.ilo.org/ilolex/cgi-lex/convde.pl?C170

Recommendations Chemical safety: - http://www.ilo.org/public/english/protection/safework/cops/english/download/e931998.pdf

• Organisation Internationale du Travail : FrenchC170 Convention sur les produits chimiques, 1990 : - http://www.ilo.org/ilolex/cgi-lex/convdf.pl?C170

Recommandations Sécurité chimique : - http://www.ilo.org/public/english/protection/safework/cops/french/download/f931998.pdf

SOURCES

INTERNATIONAL GUIDELINES


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• CIS: International Occupational Safety and health Information Center - FR: Modules de formation à la sécurité chimique http://www.ilo.org/public/french/protection/safework/cis/products/safetytm/toc.htm - EN: BASICS OF CHEMICAL SAFETY http://www.ilo.org/public/english/protection/safework/cis/products/safetytm/toc.htm

• European Agency for Safety and Health at Work : - EN: Dangerous Substances - SME friendly material http://osha.europa.eu/en/good_practice/topics/dangerous_substances/sme.stm

• International Program on Chemical Safety : INCHEM - http://www.inchem.org/

• Material Safety DataSheets : - http://www.msds.com/

• ESIS : European chemical Substances Information System - http://ecb.jrc.ec.europa.eu/esis/

TRAINING MATERIAL

INFORMATION ON CHEMICALS

Qual all wrk 043 chemical management book

Technology

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