Document DXxJ4J7DMBRbNKBbgMymVdRM

Accident l\ Prevention Manual FOR INDUSTRIAL OPERATIONS 3d edition 1955 NATIONAL SAFETY COUNCIL i' I CHICAGO U.S.A. NSC-58 Section 1: E. W. Andrews. Section 2: Dan Adair. Section 3: Leonard C. Smith. Section 4: Franklin G. Pater. Section 5: Howard C. Klopp. Section 6: Glenn F. Griffin. Section 7: Janies D. Saul. Section 8: Paul Jones. Section 9: H. Gene Miller; revised by author. Section 10: H. Gene Miller; revised by author. Section 11: Robert D. Gidel. Section 12: Roy G. Benson; revised by author. Section 13: G. G. Grieve; revised by author. Section 14: Robert L. Moore and George MacDonald; Robert L. Moore. Section 15: William N. Davis; J. C. Kato. Section 16: William N. Davis; Wendell R. Blair. Section 17: William N. Davis; f. C. Kato. Section 18: Lester W. Dutton; revised by author. Section 19: W. E. Rossnagel and Lester W. Dutton. Section 20: Lester W. Dutton. Section 21: Lester W. Dutton; revised by author. Section 22: Lester W. Dutton; G. G. Grieve. Section 23: Arthur S. Kelly; revised by author. Section 24: ' Arthur S. Kelly; revised by author. Section 25: Arthur S. Kelly; revised by author. Section 26: Arthur S. Kelly; Dan Adair. Sec tion 27: Arthur S. Kelly; revised by author. Section 28: William G. Hazard. Section 29: Floyd E. Frazier and William N. Davis; A. F. Tyra and associates and Wendell R. Blair. Section 30: A. M. Baltzer; George MacDonald. Section 31: George Mac Donald; revised by author. Section 32: Roy G. Benson; Howard H. Warzyn. Section 33: Roy G. Benson; Howard H. Warzyn. Section 34: Roy G. Benson; Howard H. Warzyn. Section 35: Howard H. Warzyn. Section 36: Floyd A. Van Atta; revised by author. Section 37: Stewart A. Washburn. Sec tion 38: Clark D. Bridges. Section 39: Floyd A. Van Atta. Section 40: Floyd A. Van Atta; revised by author. Section 41: Floyd A. Van Atta; revised by author. Section 42: C. W. Imho# and G. G. Grieve. Section 43: comp: 'd by Leonard C. Smith. Robert J. Sullivan, Senior Editor, Industrial Department, directed the technical assembly, editing, and production of this THIRD EDITION. Assisting were Editors Eilene W. Perry, James D. Saul, and Will A. Whitney. Neil T. Kinney handled art pro duction. Mildred M. Grant of the Council Library prepared the alphabetical Index. IV CONTENTS SECTION Basics of Safety.............................................................................. 1 Safety Organization............... .................. .................................... 2 Safety Committees........................................................................ 3 Removing the Hazard from the Job............................................. 4 Human Behavior and Industrial Safety....................................... 5 Safety Education............................................................................ 6 Maintaining Employee Interest in Safety..................................... 7 Puhljc Relations and Publicity for Safety................................... 8 Accident Records and Injury Rates............................................... 9 Accident Investigation, Analysis, and Costs............................... 10 Workmen's Compensation Insurance........................................... 11 Sources of Help for the Safety Man........................................... 12 Industrial Buildings and Plant Layout......................................... 13 Plant Construction and Maintenance........................................... 14 Boilers.............................................................................................15 Pressure Vessels.............................................................................16 Refrigeration Equipment...............................................................17 Handling and Storage of Materials............................................. 18 Hoisting Apparatus and Conveyors............................................. 19 Elevators and Plant Railroads.......................................................20 Power Trucks and Tractors...........................................................21 Ropes, Chains, and Slings............................................................ 22 Principles of Guarding and Transmission Guards..................... 23 Metal Forming and Shearing............... 24 Machine Tools.......................................................... 25 Woodworking Machinery................................... 26 Guarding Equipment in Selected Industries...............................27 Local Exhaust Systems and Ventilating.......................................28 Welding and Cutting.................................................................... 29 Hand and Portable Power Tools...................................................30 Jlectrical Hazards................................. --.................................... 31 Flammable Liquids......................... 32 Fire Prevention................................... --.................................... 33 Fire Extinguishment and Control...............................................34 Emergency Action Plans.............................................................. 35 Personal Protective Equipment.....................................................36 Industrial Sanitation and Personnel Facilities........................... 37 Medical, Nursing, and First-Aid Services in Industry............... 38 Industrial Hygiene............. 39 Industrial Poisons............................................ --...................... 40 Table of Chemical Hazards............... --...................................... 41 Motorized Equipment.........................-...................................... 42 Safety Engineering Tables............................................................ 43 vii INDUSTRIAL POISONS 40-7 urine. The kidneys may then become too clogged to operate at all. The possibility of arsine formation should always be considered when there is hydro gen formation around the active metals or around ores of the heavy metals, since ar senic is widely distributed in small amounts and only a trace of it is required to pro duce enough arsine to be troublesome. One of the more common sources of arsine incidents in recent years has been the han dling of dross fm the aluminum refining of metals.* Probably the most significant observation about these cases, aside from the fact that (he moisture in (he atmosphere is enough to form arsine, is the fact that the people involved in them have not been aware of the garlic-like odor which is supposed to be a warning of the presence of arsine. The extremely high acute toxicity is re flected in the threshold concentration of 0.05 ppm. Arsine, in very small -mounts, is also capable of producing a chronic type of poisoning, but it is more typically a source of acute episodes. Asbestos is a hydrated magnesium silicate found in the minerals chrysotile, amianthus, actinolite and tremolite. Practically ail the commercial asbestos is either chrysotile or amianthus, and about 90 per cent of that used in this country is chrysotile. It is used almost exclusively for heat insulation or for textiles which must resist high temperature, such as heat-resistant clothing and brake linings. Inhalation of excessive quantities of as bestos fiber can produce a fibrosis in the lungs similar to that found in silicosis but somewhat milder and usually not so rapidly progressive. Like silicosis, the condition de velops slowly and advances slowly and is equally resistant to treatment. Prevention is essentially dust control. A maximum dust concentration of 5 million particles per cubic foot has been suggested, precisely as for pure free silica. Barium, in the form of its- soluble salts, is both toxic on ingestion and inhalation and highly caustic when applied to the skin. The. carbonate and sulfide are sufficiently "Arsine Poisoning, Epidemiologic Stud ies of an Outbreak Following Exposure to Gases from Metallic Dross," Louis W. Spolyar, R. N. Harger, Archives of Industrial Hygiene and Occu[iatio)ial Medicine, 8:419<436 (I95tl)< soluble to be toxic, although not very caus tic. The sulfate, which is used as a contrast medium in X-ray work, is too insoluble to show any toxicity, and soluble sulfates are specific antidotes for ingested barium salts. Since these salts produce violent stimula tion of all muscle, upon ingestion they pro duce severe disturbances of the digestive system. After absorption, the barium salts produce an increase of blood pressure by constriction of the arterial muscle, a slow heart beac by an action similar to that of digitalis on the heart, and first excitation and then paralysis of the central nervous sys tem. In spite of the high inherent toxicity, there are few cases of industrial poisoning with barium. Barium is a heavy metal, and the dust of the insoluble salts will collect in the lungs and give rise to the condition known as baritosis. Its nodular appearance on X-ray film may be mistaken for that of silicosis. Men showing the sign of baritosis are ap parently not disabled or inconvenienced in any way. Benzene is a colorless, flammable, volatile liquid with a rather pleasant aromatic odor. Its fire hazard is between that of ethyl alco hol and that of ether. The greatest hazard is that of chronic poisoning by inhalation of comparatively small amounts over a long pe riod of time. It is one of the two or three most dangerous organic solvents in com mercial u\e. The action is primarily on the blood forming organs, producing severe anemia, bleeding under the skin, and great reduc tion in the ability of the blood to clot. The extent of chronic exposure to benzene may be determined qualitatively by measure ment of the ratio of organic to inorganic sulfates in the urine. The most convenient measurement of damage is given by a blood count. People who may be exposed to benzene vapor should have blood counts at regular intervals. Consistent change in the blood count should be closely investigated. Par ticularly significant changes are diminution in the total numbers of red cells, platelets, or white cells. Headaches, dizziness, fatigue, loss of ap petite, irritability, nervousness, nosebleed, and other signs of abnormalities of the blood may or may not be present in chronic poisoning. Substance ammonia . amyl acetate-n amyl alcohol-iso amyl alcohol-n aniline antimony (salts) arsenic arsine asbestos TABLE OF CHEMICAL HAZARDS--Continued Flash point F. Explosive limits % by volume Autoignition temperature F. Maximum acceptable concentration for Usual mode of S-hr. exposure entrance to body Signs and symptoms of poisoning Lower gas 16 Upper 25 1204 100 p.p.m.1 inhalation Severe irritation of eyes and respir atory passages, cough, caustic ac tion on skin. 77 1.1 ... 750 400 p.p.m.1,2 200 p.p.m.2* inhalation Irritation of eyes and respiratory tract, headache and dizziness, cough, nausea. 109 1.2 ... 650 . 100 p.p.m.2* inhalation Same as amyl acetate. 100 1.2 ... 700 100 p.p.m.2 inhalation --------- -------------------- (-- Same as amyl acetate. 168 1000 5 to 7 p.p.m.` absorption Acute: weakness, dizziness, blueness through skin, of lips, fainting, possible death. inhalation, or Chronic: disturbances of equilib ingestion rium, nausea, vomiting, diarrhea, eczema, sleepiness, and irritability. metal and sulfides flammable non-flammable 0.5 mg/cu.m.2* 0.15 mg/cu.m.* 0.5 mg/cu.m.2* 1 p.p.m.* 0.05 p.p.m.2* 5 m.p.p.c.f.' inhalation of dust, ingestion Acute: vomiting, colic, diarrhea, irritation of mouth and throat. Chronic: indigestion, loss of weight and appetite, sometimes severe dermatitis. inhalation of Irritation of skin, loss of hair and dust, ingestion nails, perforation of nasal septum, and direct action hoarse voice, cough, neuralgic on skin and pains, diarrhea. mucous membrane inhalation Headache, nausea, vomiting, chills and shivering, jaundice, dark or bloody urine. inhalation Chronic: shortness of breath, as bestos corns. 41-4 T A B L E O F C H E M I C A L H A Z A R D S ! N G I N li i: K I N G TABLE 43-P. A GUIDE TO VENTILATION RATES FOR TYPICAL INDUSTRIAL EQUIPMENT State or Local Regulations Should Be Consulted and Followed Where Higher Ventilation Rates Are Specified i- Operation Type of Hood Ventilation Air Flow Abrasive blast rooms (sand, Tight enclosure with grit or shot) air inlets (usually in roof) 60-100 fpm downdraft (long rooms of tunnel proportions 100 fpm cross-draft) Abrasive blast cabinets Tight enclosure with 20 air changes per minute but not access openings less than 300 fpm through all openings Usual Transport Velocity (FPM) 3500 3500 Remarks and References Ref. 8. Many codes specify minimum downdraft of 80 fpm ' Ref. 14 Asbestos Carding Spool winding Bagging Open Bag Top Enclosure Local Hoods 800 cfm per machine 50 cfm per spool Booth or enclosure (provide spillage hopper) Paper bags--100 cfm per sq. ft. open area Cloth bags--200 cfm per sq. ft. open area 3000 3000 3500 3500 Ref. 2, 15, 16. See references for details and other operations Ref. 17 Barrels -- Drums (filling or removing material by scoop) Local Hood Booth 100 cfm/sq. ft. of container cross section 100 fpm at face Belt conveyors Bins (closed top) Backet elevators * Hood at transfer point Belt speeds less than 200 fpm-350 cfm per foot of belt width, but not less than 150 fpm through open area. Belt speeds over 200 fpm--500 cfm per foot of belt width but not less than 200 fpm through open area Connect to bin top away from feed point 150-200 fpm through open area at feed points | Tight casing required 10 cfm per sq. ft. of elevator casing I cross-section ' 3500 3500 3500 Ref. 13, 18. Hood with 1-in. slot extending 120 to 180 deg con tainer. Does not confine spillage. Confine spillage--also recommended for container upsetting Ref. 17, 19 3500 t Ref. 18, 19 3500 j Ref. 18 TABLE VP. A d im TO 'rVTTT \TU'\' ii iTi.-v i.vmj -ri-nw-.r K " I SAFETY ENGINEERING TABLES 43-29 REFERENCES FOR TABLE 43-P `The Determination and Control; of Industrial Dust, by J. J. Bloomfield and J. M. DallaValle (Bulletin ,217, U. S. Public Health Service, 1935). *Exhaust Hoods, by J. M. DallaValle (Industrial Press, New York, 1952). 'Design of Exhaust Hoods for Dust Control Systems, by T. Hatch (Journal of Industrial Hygiene and Toxicology, Vol. 18, 1936, p. 595). `Air Dilution in Industrial Ventilation, by W. C. L. Hemeon (Heating and Ventilating, February 1941). `Practical Application of Industrial Exhaust Ventilation for the Control of Occupation Exposures, by B. F. Postman (American Journal of Public Health, Vol. 30, 1940, p. 149). *Principles of Industrial, Process Ventilation, by W. N. Witheridge (University of Michigan Inservice Training Course, October, 1945). 'Industrial Dusts, by Philip Drinker and Theodore Hatch (McGraw-Hill Book Co., New York, 1936). *Design of Industrial Exhaust Systems, by J. L. Alden (Industrial Press, New York, 1948). Ventilation, by W. N. Witheridge (Industrial Hygiene and Toxicology, Vol. I, Chap. 10, Edited by F. A. Patty. Interscience Publishers, New York, 1948). 'Transport Velocities for Industrial Dusts, by A. C. Stern et al (American Industrial Hygiene Associa tion Quarterly, December 1948). ''Industrial Health Engineering, by A. D. Brandt (John Wiley and Sons, New York, 1947). ''Velocity Characteristics of Narrow Exhaust Slots, by Leslie Silverman (Journal of Industrial Hygiene and Toxicology, November 1942, p. 267). "Industrial Ventilation Manual, (American Conference of Governmental Industrial Hygienists, 1952 Edition). "Code of Recommeuded Good Practice for Metal Cleaning Sanitation (American Foundrymen's Association), "A Study of Asbestos in the Asbestos Textile Industry, by W. C. Dressen et al (U. S. Public Health Service, Bulletin 241 1938). 'A Study of Dust Control Methods in an Asbestos Fabricating Plant, by R. T. Page and J. J. Bloomfield (U. S. Public Health Reports, Reprint No. 1883, Nov. 26, 1937). ''Rules Relating to the Control of Silica Dusts in Stone Crushing Operations (New York State Depart ment of Labor, Industrial Code Rule No. 34, July, 1942). "Design of Exhaust Systems, by J. M. Kane (Heating and Ventilating, November 1945, p. 68). "Foundry Ventilation, by J. M. Kane (The Foundry, February and March, 1946). "Pottery Dusts: Their Collection and Removal, by W. M. Oddie (Pottery Gazette, Vol. 53, 1928, p. 1280). ''Scrapbook of Exhaust Hoods, by J. M. Kane (Ileatiug and Ventilating. Portable Grinding--July 1950; Grinding, Polishing, Buffing--August 1950; Foundry Shakeout--November 1950; Melting Furnaces--Feb ruary 1951; Pottery--March 1951; Mixers--April 1951; and Woodworking--June 1951). "Design of Exhaust Ventilation for Solid Material Handling, by R. T. Pring et al (Industrial and Engi. neertng Chemistry, November 1949). aHartzell Blowers: Engineering Data & Installation (Hartzell Propeller Fan Company, Bulletin 1001). "The Application of Local Exhaust Ventilation to Electric Melting Furnaces, by J. M. Kane (Transac tions, American Foundrymen's Association, Vol. 52. 1945, p. 1351). "Control of Silicosis Hazard in the Hard Rock Industries. II. An Investigation of the Kelley Dust Trap for Use with Pneumatic Rock Drills of the Jackhammer Type, by T. Hatch et al (Journal of Industrial Hygiene, February 1932, p. 69). "Modified Design of Hay Dust Trap, by P. S. Hay (Journal of Industrial Hygiene, January 1930, p. 28). "American Standard for Grinding, Polishing and Buffing Equipment Sanitation (American Standards Asso ciation, Z 43-1941). "Swing Frame Grinder Dust Control, by J. M. Kane (The Foundry, August 1944). '-'>Wbat IVe Make (B. F. Sturtevant Co., Catalog No. 500). `"Ventilation of Motion Picture Booths, by P. Drinker and J. R. Snell (Journal of Industrial Hygiene and Toxicology, April 1938, p. 321). "How to Justify an Industrial Air Conditioning Investment, by P. J. Marschall (Heating, Piping and Air Conditioning, February 1952, p. 71). "How to Design Exhaust Hoods for Quartz-Fusing Operations, by E. C. Riley et al (Heating and Venti lating, April 1940, p. 23). "A Study of Quartz-Fusing Operations with Reference to Measurement and Control of Silica Fumes, by E. C. Riley and J. M. DallaValle (U. S. Public Health Reports, Vol. 54, 1939, p. 532). "Ventilation of Open Tanks, by A. C. Stern (American Industrial Hygiene Association, Industrial Hygiene Quarterly, Sept. 1950). "American Standards for Safety in Electric and Gas Welding and Cutting Operations (American Standards Association, Z 49.1). "Rules Relating to the Removal of Dust, Gases, and Fumes (New York State Department of Labor, Indus trial Code Rule No. 12, Jan. 1931). "Energy Losses at Suction Hoods, by A. D. Brandt and R. J. Steffy (A.S.H.V.E. Transactions, Vol. 52, 1946, p. 205). "Resistance Test on Pipe, by A. Nutting (Mechanical Engineering, May 1938). '"Design of Injector for Low Pressure Air Flow, by G. E. McElroy (U. S. Bureau of Mines, Technical paper 678). "American Standard Safety Code for Ventilation and Operation of Open Surface Tanks (American Stand ards Association, Z 9.1-1951).