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INDUSTRIAL HYGIENE A Vital Component In Manufacturing Safety
Course Objectives This training course will cover…
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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
Industrial Hygiene
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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
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“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 Applications in IH
Physics, math, anatomy, physiology Hazard evaluations of noise, illumination, lasers, radiation, and ergonomics
Chemistry, anatomy, physiology, toxicology
Toxic chemical exposure evaluations of carcinogen hazard assessment and reproductive hazard assessments
Physics, chemistry, statistics Measuring exposures to chemical and physical agents, interpreting lab analytical reports. Use of direct reading instruments.
Statistics, epidemiology, physics, chemistry, anatomy, physiology, toxicology, language skills
Interpreting study and lab results, critical review of research, performing research
Language skills Interactions with workers, management, and customers; writing reports and papers; design of programs
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Scope of Industrial Hygiene Anticipation, Recognition, Evaluation, and Control of hazards/agents…
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Chemical Physical
Biological Ergonomic
Dusts, Mists, Fumes, Vapors, Aerosols, Gases
Ionizing Radiation, Nonionizing Radiation,
Noise, Vibration, Temperature Extremes
Insects, Yeasts, Molds, Fungi, Bacteria, Viruses
Monotony, Fatigue, Repetitive Motion, Deviated Posture,
Static Posture
Why Apply IH in Manufacturing The Bottom Line
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All organizations have a moral & legal obligation
to protect their employees!
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More Reasons For Applying IH in Manufacturing
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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)
Five of every 100 workers will suffer an illness or injury
from work this year. (Bureau of Labor Statistics)
For every $1 invested in safety, a company saves between $3 and
$6. (Liberty Mutual Research Institute)
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1. To prevent serious injuries, illnesses & fatalities in the workplace
2. Avoid citations and penalties
Final Reasons For Applying IH in Manufacturing
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)
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Exposure Assessment Strategy
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Qualitative Exposure Assessment Includes an evaluation of potential exposures via
inhalation, ingestion, dermal contact, physiological interactions, and ergonomic factors.
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Review Operations/Processes
Observe Worker Activities
Review Past Records
Review of current government regulations &/or
technical guidelines
Review Hazards
Qua
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Qualitative Exposure Assessment Continued
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Evalua�ng Risk Factors:
Frequency (how o�en) Intensity (how much) Dura�on (how long) Individual Sensi�vity 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.
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Determine Sampling Strategy
Analyze/Interpret Results
Implement Corrective Actions
Document Results
Determine Timeframe for Re-Sampling Q
uant
itativ
e Ex
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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)
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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
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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
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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
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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)
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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
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Sampling Methodology – Where?
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Personal Exposure
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.
Area Monitoring
NOTE: Location(s) is dictated by NEED.
Source of contaminants is dictated by AREA.
Sampling Methodology – When?
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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: 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
Integrated Sampling
Sampling can be representative of a very short period of time or of a typical work day.
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Sampling Methodology – When? Continued
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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?
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Direct Read Equipment
Colorimetric Tubes
Draeger Pump Dosimeter
GM Detector PID
Dosimeter
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Sampling Methodology – How?
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Integrated Sampling
Filter Cassettes
Flowmeters Air Sample Bags
Sorbent Tubes
Passive Dosimeters Universal Air Sampling Pumps Cyclone
Filter Assembly
Sampling Trains
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Universal Pump Connected To A Sorbent Tube Calibration Train
Sampling Train Using A Pre-Filter Cassette & A Sorbent Tube
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Sampling Trains Continued
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Glass Impinger & Glass Trap In Calibration Train
Sampling Train For Filter Assembly With A Cyclone
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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)
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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:
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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
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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
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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)
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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 and chronic health effects.
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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.
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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
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Specific Hazards
Air Contaminants Formaldehyde Wood Dust Particulates Volatile Organic Compounds (VOCs) Chromium (VI) (Hexavalent Chromium)
Noise
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29CFR SUBPART Z
11991100..11000000 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
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Z TABLE EXAMPLES (29CFR1910.1000)
SUBSTANCE 8-‐HOUR TWA CEILING PEAK
Acetone 1000 ppm
Benzene 10 ppm 25 ppm 50 ppm
Carbon Monoxide
50 ppm
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
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Formaldehyde
Health Effects
hypersensitivity
OEL Limit= 0.5 ppm 0.75 ppm 2 ppm 0.3 ppm (C) 0.016 ppm; 0.1 ppm (C)
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Formaldehyde Continued Analytical Method
2016: DNPH Silica Gel Tube 3500: Impinger 205: Passive Monitor
Controls
Other Regulatory Requirements per 1910.1048
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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)
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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
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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)
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Particulates Not Otherwise Regulated (PNOR) Continued
Analytical Method 0500 (total dust): 37 mm PVC filter 0600 (respirable dust): 37 mm PVC filter w/ cyclone
Controls 95 –P100
filtration
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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
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NOTE: Additive exposure calculations if similar toxicological effect (C1/T1+ C2/T2+ C3/T3+ … should not exceed 1)
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Volatile Organic Compounds (VOCs) Continued
Analytical Method 1500, 1501, 1550…
Controls
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Chromium (VI) (Hexavalent Chrome) Sources plastics
to paints, primers and other surface coatings
chromium alloys
Health Effects
(lung, nasopharynx, oropharynx, nasal passages)
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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= 0.0002 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
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Noise OSHA Regulation Noise Measurement & Control Hearing Tests Hearing Protection Hearing Conservation Program Management
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Questions?
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