Course Objectives. INDUSTRIAL HYGIENE A Vital Component In Manufacturing Safety 3/24/14. This training course will cover

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1 INDUSTRIAL HYGIENE A Vital Component In Manufacturing Safety Course Objectives This training course will cover Industrial Hygiene What is industrial hygiene? Scope of industrial hygiene How does industrial hygiene apply to manufacturing? Development of an industrial hygiene plan/sampling strategy Exposure monitoring/assessment Using the results 1

2 Introduction Industrial hygiene is Part science, part art The application of scientific principles in the workplace to prevent the development of occupational disease or injury Requires knowledge of chemistry, physics, anatomy, physiology, mathematics, toxicology, epidemiology, statistics The science and art devoted to the anticipation, recognition, evaluation, and control of those workplace stresses, environmental factors, or other hazards, which may cause sickness, impaired health and well-being, or significant discomfort among workers or among the community - ACGIH Knowledge Basis for IH Disciplines Involved Physics, math, anatomy, physiology Chemistry, anatomy, physiology, toxicology Physics, chemistry, statistics Statistics, epidemiology, physics, chemistry, anatomy, physiology, toxicology, language skills Language skills Applications in IH Hazard evaluations of noise, illumination, lasers, radiation, and ergonomics Toxic chemical exposure evaluations of carcinogen hazard assessment and reproductive hazard assessments Measuring exposures to chemical and physical agents, interpreting lab analytical reports. Use of direct reading instruments. Interpreting study and lab results, critical review of research, performing research Interactions with workers, management, and customers; writing reports and papers; design of programs 2

3 Scope of Industrial Hygiene Anticipation, Recognition, Evaluation, and Control of hazards/agents Chemical Physical Dusts, Mists, Fumes, Vapors, Aerosols, Gases Ionizing Radiation, Nonionizing Radiation, Noise, Vibration, Temperature Extremes Biological Ergonomic Insects, Yeasts, Molds, Fungi, Bacteria, Viruses Monotony, Fatigue, Repetitive Motion, Deviated Posture, Static Posture Why Apply IH in Manufacturing The Bottom Line All organizations have a moral & legal obligation to protect their employees! 3

4 More Reasons For Applying IH in Manufacturing Every day, an average of 9,000 U.S. workers sustain disabling injuries on the job, 16 workers die from an injury at work, and 137 workers die from work-related diseases. (National Institute for Occupational Health and Safety) For every $1 invested in safety, a company saves between $3 and $6. (Liberty Mutual Research Institute) Five of every 100 workers will suffer an illness or injury from work this year. (Bureau of Labor Statistics) Final Reasons For Applying IH in Manufacturing 1. To prevent serious injuries, illnesses & fatalities in the workplace 2. Avoid citations and penalties DAILY NEWS HEADLINES Industrial accident at aluminum plant kills 1, injures 1 (11/15/12) Pennsylvania worker dies following exposure to toxic chemicals (2/21/13) Factory worker dies from chemical burns in industrial accident (2/26/13) Worker dies from exposure to chlorine dioxide (12/19/13) 4

5 Exposure Assessment Strategy Qualitative Exposure Assessment Includes an evaluation of potential exposures via inhalation, ingestion, dermal contact, physiological interactions, and ergonomic factors. Qualitative Exposure Evaluations Review Operations/Processes Observe Worker Activities Review Past Records Review of current government regulations &/or technical guidelines Review Hazards 5

6 Qualitative Exposure Assessment Continued Evaluang Risk Factors: Frequency (how oen) Intensity (how much) Duraon (how long) Individual Sensivity Toxicity of the Chemical Quantitative Exposure Assessment Includes baseline industrial hygiene surveys and periodic resurveys of work areas and operations as needed to identify and evaluate potential worker health risks. Quantitative Exposure Evaluations Determine Sampling Strategy Analyze/Interpret Results Implement Corrective Actions Document Results Determine Timeframe for Re- Sampling 6

7 Situations Warranting IH Monitoring Employee complaint of exposure to a chemical; Procurement of a new chemical which raises a health concern; Design change/review involving chemicals or other environmental factors/stressors associated with work and work operations that may cause sickness or impaired health noise non-ionizing radiation (i.e., IR, UV) Ionizing radiation magnetic fields Certain contaminants as required by OSHA (i.e., lead, beryllium, asbestos, welding on paint, etc.) Whenever occupational exposure exceeds 10% of the Occupational Exposure Limit (OEL) Sampling Procedures & Methodology There are many sources that provide specific sampling and analytical methods for chemical contaminants The U.S. Occupational Safety and Health Administration (OSHA) sampling and analytical methods OSHA Technical Manual National Institute for Occupational Safety and Health (NIOSH) analytical methods American Society for Testing and Materials (ASTM) sampling and analytical methods Traveler s Air Sampling Guidelines Private laboratories 7

8 Sampling Procedures & Methodology A sampling strategy is the overall plan for conducting the exposure assessment. The strategy developed depends upon the reason for evaluation Compliance, Health Research OR Engineering Control Testing, Surveillance Sampling Methodology What? 1. What will be sampled? Considerations include: The level of risk (i.e., worst first) Regulatory requirement Signs or symptoms of exposure Employee requests for respirators History of high exposures New materials/process 8

9 Sampling Methodology Who? Where? When? How? 2. Who will be sampled? 3. Where will the sampling be conducted (i.e., personal breathing zone vs. area monitoring)? 4. When will the sampling be conducted? 5. How will the sample be collected (including the type(s) of collection equipment) Sampling Methodology Who? When selecting personnel to monitor, you must first determine the purpose for monitoring COMPLIANCE Sample maximum risk employee(s) likely to have the highest exposure COMPREHENSIVE ASSESSMENT Random sample of employees by exposure group 9

10 Sampling Methodology Where? Personal Exposure Monitoring Area Monitoring Personal breathing zone (mouth & nose area that is a 10 inch radius from employee s nose). Employee wears sampling media for duration of work shift to compare exposure to TWA, STEL &/or Ceiling Limits. Sampling at specific areas in the operation. Worst case scenario sampling. NOTE: Location(s) is dictated by NEED. Source of contaminants is dictated by AREA. Sampling Methodology When? Sampling can be representative of a very short period of time or of a typical work day. Direct Read Equipment Direct Read: Equipment that provides an instantaneous read out of the exposure. Sound Level Meters Noise Dosimeters Photo Ionization Detectors Particulate Counters IR Spectrophotometers (>100 contaminants in library) Colorimetric Detector Tubes Integrated Sampling Integrated Sampling: Passing a known volume of air through a selective media for analysis by an AIHA accredited laboratory. Personal Sampling Pumps Filter Media PVC, MCE, Charcoal, etc. Passive Dosimetry 10

11 Sampling Methodology When? Continued When to sample is also influenced by the information required Type of operation assessed Batch vs Continuous Multiple shifts Geographic/Climatologic conditions Sampling Methodology How? Direct Read Equipment Dosimeter Draeger Pump Dosimeter PID Colorimetric Tubes GM Detector 11

12 Sampling Methodology How? Integrated Sampling Filter Cassettes Sorbent Tubes Flowmeters Air Sample Bags Passive Dosimeters Cyclone Filter Assembly Universal Air Sampling Pumps Sampling Trains Sampling Train Using A Pre-Filter Cassette & A Sorbent Tube Universal Pump Connected To A Sorbent Tube Calibration Train 12

13 Sampling Trains Continued Glass Impinger & Glass Trap In Calibration Train Sampling Train For Filter Assembly With A Cyclone Sampling Methodology How? Instrument choice depends upon Portability & Ease of Use Efficiency & Analytical Method Reliability Under Various Conditions of Field Use Temperature Extremes Humidity/Moisture Wind Chemical Interferences Shock (i.e., ruggedness/durability of equipment) 13

14 Sampling Methodology How Many? There is no set rule! But, when conducting a comprehensive assessment, a minimum of 6 (six) samples for each exposure group may be necessary for a decision of acceptability. NOTE: A blank should be included with every set of samples! Sampling Methodology - How Frequent? Rule of Thumb: 14

15 Sampling Methodology Associated Activities While sampling is in process, it is important to obtain information that could prove useful in interpreting results Description of the process/activity Description of adjacent operations Environmental conditions Ventilation system performance Work practices Sampling Methodology Associated Activities When sampling is completed, there are several activities that still must be completed Sample collection/retrieval Post-calibration of sampling equipment Documentation/Recordkeeping Chain of Custody (COC) Air Sampling Worksheet Sound Level Survey Form Employee Exposure Monitoring Notification Form Calibration Records Sample packaging and shipment 15

16 Interpretation of Sampling Results Sampling results should be compared against established exposure limits OSHA PELs (Permissible Exposure Limits) ACGIH TLVs (Threshold Limit Values) ACGIH BIEs (Biological Exposure Indices) NIOSH RELs (Recommended Exposure Limits) NIOSH IDLHs (Immediately Dangerous To Life and Health) AIHA/OARS WEELs (Workplace Environmental Exposure Levels) Occupational Exposure Limits 1. Time Weighted Average (TWA) 8-hour time weighted average exposure 2. Short Term Exposure Limit (STEL) 15 minute time weighted exposure that should not be reached more than 4 times daily, separated by 60 minute intervals 3. Ceiling Limit (C) Limit that should never be exceeded 4. Excursion Limit (EL) Should not exceed 3 times the TWA for more than 30 minutes 5. Action Limit (AL) Concentration that requires additional action (e.x. medical surveillance, personal exposure monitoring, training, etc) NOTE: Occupational exposure limits (OELs) are developed for protection of healthy workers. OELs are based on repeated daily exposures over a working lifetime. They are normally averaged over an 8-hour workday and serve to protect against acute - INTERNAL and chronic - health effects. 16

17 CORRECTIVE ACTION If sampling results are below established exposure limits then no further action may be required. Sampling results are at or above established exposure limits may indicate the need for corrective actions. If sampling results are at or above the IDLH then corrective action should be implemented immediately. CORRECTIVE ACTION CONTINUED Engineering Controls Noise Attenuation Ventilation Isolation Administrative Controls Work-Area Access Restrictions Change In Work Practices Material Substitution Job Rotation Personal Protective Equipment Eye, face, hand, hearing, body, head, foot protection Respiratory Protections Fall Protection 17

18 Specific Hazards Air Contaminants Formaldehyde Noise Wood Dust Particulates Volatile Organic Compounds (VOCs) Chromium (VI) (Hexavalent Chromium) 29CFR SUBPART Z Air Contaminants: Includes Z Tables which establish worker exposure limits for specific listed substances Employee exposure cannot exceed limits Tables Z-1, Z-2, Z-3 each have their own requirements PEL = Permissible Exposure Limit 18

19 Z TABLE EXAMPLES (29CFR ) SUBSTANCE 8- HOUR TWA CEILING PEAK Acetone 1000 ppm Benzene 10 ppm 25 ppm 50 ppm Carbon 50 ppm Monoxide Chlorine 1 ppm Chromium (VI) 5 μg/m³ Formaldehyde 0.75 ppm PNOR 15 mg/m³ (total dust) 5 mg/m³ (respirable dust) Styrene 100 ppm 200 ppm 600 ppm Toluene 200 ppm 300 ppm 500 ppm Formaldehyde Health Effects hypersensitivity OEL Limit= 0.5 ppm 0.75 ppm 2 ppm 0.3 ppm (C) ppm; 0.1 ppm (C) 19

20 Formaldehyde Continued Analytical Method 2016: DNPH Silica Gel Tube 3500: Impinger 205: Passive Monitor Controls Other Regulatory Requirements per Wood Dust Health Effects OEL Particulate Not Otherwise Regulated OSHA PEL=15 mg/m3 (total dust) OSHA PEL= 5 mg/m3 (respirable dust) Wood Dust ACGIH TLV= 0.5 mg/m3 (western red cedar) ACGIH TLV= 1 mg/m3 (all other wood dusts) NIOSH REL= 1 mg/m3 (hard woods, soft woods, western red cedar) 20

21 Wood Dust Continued Analytical Method 0500 (total dust): 37 mm PVC filter 0600 (respirable dust): 37 mm PVC filter w/cyclone Controls 95-P100 filtration Particulates Not Otherwise Regulated/Specified (PNOR/PNOS) Acceptable use of the PNOR/PNOS exposure limits OEL OSHA PEL=15 mg/m3 (total dust) OSHA PEL= 5 mg/m3 (respirable dust) ACGIH TLV= 10 mg/m3 (total) AGCIH TLV= 3 mg/m3 (respirable) 21

22 Particulates Not Otherwise Regulated (PNOR) Continued Analytical Method Controls 0500 (total dust): 37 mm PVC filter 0600 (respirable dust): 37 mm PVC filter w/ cyclone 95 P100 filtration Volatile Organic Compounds (VOCs) Sources Health Effects OEL [See OEL for individual contaminants] Benzene: PEL TWA= 1 ppm; STEL=5 ppm; TLV -TWA=0.5 ppm; TLV-STEL=2.5 ppm Toluene: PEL TWA=200 ppm; TLV-TWA=50 ppm Xylene: PEL TWA=100ppm; TLV-TWA=100 ppm; TLV-STEL=150ppm VM&P Naphtha: TLV TWA= 300 ppm NOTE: Additive exposure calculations if similar toxicological effect (C1/T1+ C2/T2+ C3/ T3+ should not exceed 1) 22

23 Volatile Organic Compounds (VOCs) Continued Analytical Method 1500, 1501, 1550 Controls Chromium (VI) (Hexavalent Chrome) Sources plastics to paints, primers and other surface coatings chromium alloys Health Effects (lung, nasopharynx, oropharynx, nasal passages) 23

24 Chromium (VI) (Hexavalent Chrome) Continued OEL Limit= 2.5 μg/m³ 5 μg/m³ 0.01 mg/m³ (insoluble) 0.05 mg/m³ (water-soluble) NIOSH REL= mg/m³ Analytical Method 215: low ash 37 mm or 26 mm PVC filter 4001: 37 mm PVC filter or 37 mm quartz fiber filter Controls Substitution Noise OSHA Regulation Noise Measurement & Control Hearing Tests Hearing Protection Hearing Conservation Program Management 24

25 Questions? 25