Document gDV8RN6Q3wv5yZEd4X7MdgRQG

FILE NAME: National Safety Council (NSC) DATE: 1946 DOC#: NSC118 DOCUMENT DESCRIPTION: NSC - Accident Prevention Manual for Industrial Operations t- I Q ..1 ^ ' Mitf<*ij-3 H Ur 12* Pf ACCID ENT PREVENT IO N FOR INDUSTRIAL OPERATIONS ` " *Y Vi vfMiA'A.vcv 'r riOm IgSp a 4 2 M V N iH IS k / 7 |l>7 c m m m h x j * > v * l '. THIS H ip P jP v -lfe is published by the National Safety Council as a part of the service materials provided for its industrial members. \ The MANUAL is revised from time to time. The comment of its users is therefore solicited in matters of accuracy and completeness, particularly in regard to hazards arising from the in tro d u c tio n into industry of new materials, new equipment and new , ' i processes.. ii ACCIDENT PREVENTION MANUAL FOR INDUSTRIAL O PE RA TIO N S including a statement of methods used in setting up a safety organization, of means used to enlist employee co-operation, and of materials and services offered by the National Safety Council. Prepared by the engineering staff of the Industrial Division, National Safety Council, with assistance from the Statistical and Traffic and Transportation Divisions on problems relating to their fields. Especial appreciation is due the many members of the Manual Committee and to other consultants, who exam ined preliminary drafts and proofs, and who gave inval uable advice by correspondence and in conference. P rinted by W m. H. P ool Co. Chicago, Illinois 1946 iii FOREWORD For some years there has been need for a compact source of basic information on accident prevention in industry. The body of safety engi neering knowledge has expanded tremendously since the first concerted efforts were made at the beginning of the century to reduce industrial losses. The National Safety Council and many other agencies have in the interim published the result of their experience and research in many forms. Until the publication of this book there has not been, however, one volume which has presumed to serve as a ready reference which would put the safety director immediately on the trail of the answer to all but the most unusual of his safety problems. The Safe Practices Pamphlets and Data Sheets, long established as technical publications of the National Safety Council, give more extensive discussion to accident prevention problems than does the MANUAL. They are valuable complements to the MANUAL, but in no sense are they super seded by it. Obviously no volume could encompass the details of accident preven tion engineering for every industrial operation, nor even for the operations common to most industries. Industrial safety in specific application means close analysis of the operation in question, the design and control of equip ment and environment so as to reduce the hazard, and the training of the employee toward safe attitudes and practices. The variables of safety in action are infinite. They can be discussed and illustrated in a single volume only in terms of certain common characteristics. The MANUAL is not a textbook covering the general field of accident prevention theory, nor does it attempt to include the special problems of specialized industries. Neither does it attempt to discuss ways and means by which the employer can properly deal with the off-job hazards of his employees or participate in the public safety problems of his community. The engineering problems of many special industries, and highway, home and farm safety programs are more appropriately a part of other Council publications. The MANUAL is a comprehensive source of the "how" of safety, in tended to be kept at hand for frequent and ready reference by the safety director, the safety engineer and the foreman. It sets forth the principles of safety for activities in which the great majority of manufacturing indus trialists engage. It carries these principles into as much detail as it can without contradicting the premise stated above that the application of acci dent prevention methods to the specific job must remain the responsibility of the engineer. Such application necessarily involves a degree of ingenuity and executive capacity as well as the extensive use of technical materials from the National Safety Council and from other sources. r v 282 CHEMICAL HAZARDS Substance acetaldehyde acetanilide acetic acid acetone acetylene acrolein acrylonitrile aluminum (powder) ammonia amyl acetate--n amyl alcohol--n aniline Flash point F. --17 345 104 0 gas 32 gas 76 100 168 TABLE VII-B--`TABLE OF CHEMICAL HAZARDS (See paragraphs immediately preceding Table) Explosive limits % by volume Auto ignition Probable safe temperature concentration for F. 8-hr. exposure Usual mode of entrance to body Lower Upper 4.0 57 365 less toxic than formaldehyde inhalation -- 4.0 2.55 12.8 less toxic than aniline 1050 1000 200 p.p.m.1," inhalation, ingestion inhalation 2.5 80 635 none adopted extremely low toxicity <1.0 p.p.m." inhalation inhalation 3.05 898 20 p.p.m.1 inhalation .035 oz./cu.ft 16 25 1085 none adopted 1204 100 p.p.m.1 inhalation 1.1 714 400 p.p.m.1' " inhalation 1.2 700 100 p.p.m." inhalation 1000 5 to 7 p.p.m." absorption through skin, inhalation or ingestion Signs and symptoms of poisoning Irritation of eyes and respiratory tract, cough, difficult breathing, night sweats. Blueness of lips and fingertips, confusion, dizziness. Powerful skin irritant. Irritation of skin, eyes, and upper respiratory tract. Headache, nausea, suffocation at very high concentrations. Extreme irritation of the eyes, skin and respiratory tract. Hydrogen cyanide effect due to decomposition in body. Severe irritation of eyes and re spiratory passages, cough, caustic action on skin. Irritation of eyes and respiratory tract, headache and dizziness, cough, nausea. Same as amyl acetate. Acute: weakness, dizziness, blue^ ness of lips, fainting, possible death. Chronic: disturbances of eciuilibrium, nausea, vomiting, diarrhea, ccis-ma. sleepiness ar.d irritability. TABLE OF CHEMICAL HAZARDS--Continucd Flash point Explosive limits Auto ignition Probable sale tempoeTr7ature cOon1.cr 'tion for Usual mode of i n f r 'l n r A t n Signs and symptoms of noisonine I ( ..........................................................- .......... - ......... 1 Substance antimony (salts) arsenic * arsine. asbestos barium (compounds) benzene (benzol) bromine Flash point F. Explosive limits % by volume Auto- ignition Probable safe temperature concentration for F. 8-hr. exposure . Lower Upper metal and sulfides flammable unknown, probably like arsenic 0.15 mg/cu.m.0 - 1 p.p.m.8 non-flammable peroxide, chlorate, and nitrate produce violent combustion in flammable materials 5 million particles per cubic foot' none adopted 12 1.5 8 1000 100 p.p.m.8 1 p.p.m.9 ' - Usual mode of entrance to body Signs and .symptoms ma. ki of poisoning- 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, an^ 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 inhalation or ingestion of soluble salts, direct action on skin inhalation inhalation direct attack on skin and mu cous membranes Chronic: shortness of.breath, as bestos corns. ' Severe dermatitis from the caustic salts, vomiting, dyspnea, abdom inal pain, cyanosis, paralysis. Chronic: weakness, fatigue, bleeding.from the gums and nose, head ache, dizziness. Acute: in e b ria tio n , convulsions, and loss of consciousness. Irritation of eyes and respiratory tract, irritation and corrosion of skin, probable lung irritation in acute cases. 283 T A B L E OF C H E M I C A L H A Z A R D S 'M shoii indi y. carie|i 1 -the; i the at* J- filter hard? eted,-; :ely tci. 'e r fy g l 3| *"*" ed inf i e x |g ce -sH ondi liable 1 l.d ;-.bc/|* T.orjjl in <>jj clean' ( ubricftll from ,|j sed,( . *1 sMetlI e cr.\ ) jor / P A R T `X I I I \ INDUSTRIAL HYGIENE Plant facilities: comfort ventilation . . . common ventilation methods . , . industrial - illumination . . . . . : . . . . . . . . ;. .pp. 441-448 sanitary facilities . . . eating facilities (education of employees, food handling, contamination, dishwashing) ..................................................................pp. 448-453 'Plant- services:' 'medical -'Service quarters . , .-physical examinations . . . personnel . and supplies -----. .....-- .-- -------- -- --------, -- .. pp. 453-457 Occupational diseases: environmental diseases . infections of occupation..-.. . . ....... .................................... . . .... ....... ................... ..... . ............ .pp. 457-460 Industrial .poisons: metals and other organic substances . . . radio-active elements . . metalloids . . . non-metals.............................. ................. .. . ..... .pp. 460-463 gases . . . organic compounds aromatic compounds.................... pp. 463-466 -.Industrial skin diseases : . ...................: ................ pp. 466-467 Principles of industrial disease control: substitution . . . isolation . . . pprroocceessss r--evision general ep-xvh-Kaaunsstt vveennttiillaattiioonn .-. ; local exhaust'-ventilation- pp.. 467-4-72 Table XIII-C. Minimum Standard^ of Illumination....................................PP- 472-477 , Plant. Facilities v -tonncreas^ An increase or decrease of Factors in comfort ventilation* .l;.r:y;'y;:rnoistu^ ,The comfort, health and efficiency of in dustrial workers depends, as it does with ;,alL,of..us,, upon ,,the `condition of the air Carbon dioxide. The exhaled air contains approximately 100 times more carbon di oxide than does the air breathed into the creased production and improved morale of ^workers for the investment made in proper -ventilation of workrooms; " . lungs. This may increase the carbon di oxide content of the room atmosphere, but is of little^ or no importance from a venti lation point of view, due to the fact that *'/" After being confined in work places, air room air is diluted by air leakage from 'undergoes -certain physical, and chemical , the .`outside through structural -cracks .:ang.y; ^ changes which -may make it unpleasant or crevices. Kunhealthful. These changes usually include: Oxygen.; The' air breathed into the lungs An increase of carbon dioxide . A decrease of oxygen ...... An addition of bacteria . contains more than 20 per cent oxygen, but the air exhaled contains little mor .than 15 per cent of this gas, producing a con tinuous decrease of oxygen in the room air. , :An addition of odors However, it has been determined that the An addition of objectionable -oxygen content of- the room ir. must be dusf, fumes, gases or- vapors . reduced to 15 per cent before any ill effects will be noted. 1 y For the . engineering aspects of general ventila- 'Inasmuch, as the average breath contains ^and ` ' xnst ^ventilation control. ?ystems .see : V:-Part I "Design and Layout" and. .the section o n . -oniy 20 cubic inches of air, it is improbable iP M l exhaust ventilation- in this Far.. Sc.References" , also. 8S; 441 462 INDUSTRIAL HYGIENE in suspected cases of poisoning from ex posure to zinc, these other toxic elements should not be overlooked. The only significant physiological effect of zinc appears to be metal fume fever. Although of transient character the fever, chills and sweating may be sufficiently se vere to cause disability of one or two days' duration. The salts of this metal have an irritant effect on the skin. figuring phosphorus poisoning is now sr! dom seen. It has been eliminated by 111< change from the poisonous white form in the innocuous red phosphorus. The ]>. soning is always chronic. Exposure to phosphine (phosphorus by dride) may occur rarely in pickling opera tions and in the manufacture of ferrosiii con. This gas causes respiratory and gastro-intestinal disturbances, generalized Zirconium. No evidence of poisoning weakness and, if the exposure is great, eon due to this metal has been reported. There viilsions. are, however, certain fire and explosion Selenium. Of increasing industrial ap hpoazwadredrsedasmsoectiaalteadndwiitths hthyedrhidaen.dling of the pploiucantdiosn,aresesleynsituemmic apnodisointss asnoldubilreritactoimiiy.j | to the skin and mucous membranes. 1 V Industrial poisons (Radio-active elements) Tellurium is similar to selenium in it- ! Radium, thorium, uranium, radon, x-ray effects and symptoms. (See section on radiation, Page 459.) Industrial poisons Industrial poisons (Metalloids) Antimony. The action of antimony is similar to that of arsenic and lead, but not so severe. Antimony can be very irri tating to the skin and mucous membranes. Systemically, it resembles lead in its (Non-metals) Boron. Compounds of boron are toxic, but no industrial poisoning has been im ported. Carbon disulfide, a widely used solvent, is a strong nerve poison if absorbed con tinuously. gastro-intestinal effects, but it usually Chromium. Chromic acid, chromate and causes diarrhea instead of constipation. In dichromate salts are extremely irritatitp; suspicious cases both lead and arensic must to the skin, eyes and all mucous mem be ruled out. branes. Arsenic. A frequent industrial health Silicon. The dioxide, so-called "free hazard results from the arsenic sulfide con silica," is the cause of a fibrotic disease <d tamination of the ores of heavy metals. Arsenic compounds also have wide appli cation in a number of industries. When ever contact with acid occurs, there is a possibility of arsine being formed. Such formation is to be guarded against in the cleaning of tank cars which have contained concentrated hydrochloric or sul furic acid. Arsine is extremely poisonous, completely destroying the red blood cells in a relatively short time. the lungs which, if it progresses, will -eventually limit the respiratory function. Exposure for long periods (usuallyyears) to excessive concentrations of finch divided dust containing high percentages of free silica are followed by the characlci istic symptoms of this lung disease. Tu berculosis frequently follows, Ashes/"' causes a similar disability. Sulphur is not a cause of industrial pm soning, but it may produce skin irritation Manganese. The most frequent source of manganese poisoning is in ore handling, especially in the dusty operations of sepa Some of its compounds, for example. hydrogen sulfide, are extremely -toxic. It is not only irritating, especially to the eyes, ration and grinding. Disturbances of the but it has a marked systemic effect in pro central nervous system similar to those of during paralysis of the respiratory center. paralysis agitans occur, progressing from general muscular weakness, tremors of the extremities, spasticity, emotional upsets, speech peculiarity, mask-like expression, and ultimately complete disability. Hydrogen sulfide may be produced in many industries where sulphur-containine compounds, especially sulfides, come in contact with dilute acids. Sulfur dioxide, a com m on result of gas and coal combustion, Phosphorus. Formerly frequent in the has the irritant action of all the acid gases match and fireworks' industry, horribly dis on the respiratory tract. 1 by form "'he poi TfftV; g opera 'errosilb iry and leral /ed ;at, -con- rial ap e comritalmg . in 11H : toxic, ;en .je-x olvent, dcoii- and ita ting mem- "frs' ase of , w.ll non. sualiy finely res of acte . Ti >estos 1 poi-. ation mpb, It eyes, ; prointer, d in imru i.;:. in ie, i u es IS ' rii I N D U S T R I A L POISON'S' pij st "Titanium, tungsten, molybdenum, gernanium. No cases of poisoning due to Some, like hydrogen sulfide, may have other than local irritant actions `(see above). -.these elements, used in the steel. industry, \ have been reported. The chlorides hydroiize to produce acids which are irritating. The effects of these gases depends-to a _ large degree upon the site of irritation and ffs ig g g g bility of the gases in water. Those with a [Industrial poisons ' (Gases)..... '.............................................. hOxygen.. Atmospheres, extremely rich in oxygen are unlikely to occur industrially, but it has been shown that prolonged ex posure to high concentrations are irritating to the respiratory tract. Nascent oxygen, ,n the form of ozone, is also an irritant. 1 Hydrogen is inactive physiologically and is of interest only because of its' explosive nature In its evolution from pitting baths 'it may act, by means of small bubbles, as a 'carrier for toxic or irritating substances. ,...Nitrogen, used occasionally in industry as 'an inert gas to prevent explosive mix tures, may displace oxygen to a dangerous high solubility exert their greatest effect in the upper respiratory passages, Those with a lower solubility, and those, like phosgene, which hydrolize to form acids, reach the deeper portions of the lungs and bronchi. As a rule, the results of exposure to this latter type are more severe, for no early irritation occurs tp give warning i;<The in sidious, delayed effects may end3in pulmonary'-edema, pneumonia, and death. This , effect is also true of a larger number of organic compounds of comparablej -char-- acter. ( ~ ^ _ Helium (also other rare gases). Not sign ificant toxicologically, helium is now of value for supplying to divers a mixture with oxygen to prevent compressed-air extent "In those who work under increased atmospheric pressure, nitrogen, because of its physiological inertness, may cause severe damage when released from the tissues. [Nitrogen's hydride, ammonia, is extremely 1irritating to the eyes and the respiratory illness. (See "increased atmospheric pres sure," Page 459.) This mixture eliminates the effects due to nitrogen, which is soluble in body tissues. .t < Carbon monoxide. The most common cause of gas poisoning, carbon monoxide, is not only encountered In practically every 7 The toxic oxides of nitrogen have be industry, but also in everyday life. It acts come important because of their formation as an asphyxiant by forming a stable com during' the high temperatures of welding pound with hemoglobin, thus preventing operations. Whenever nitric acid is used, transport of oxygen by the blood -- - the formation of these gases should be considered. They act as acids, irritating .the respiratory tract so severely "that pul monary edema and pneumonia may result. 'Nitric oxide exerts its action by the oxida" tion of hemoglobin to methemoglobin with Acute poisoning is the most frequent form, but signs of chronic exposure are recognized^ The dioxide of carbon^ may' displace air and thus produce asphyxia. It is a powerful respiratory stimulant and may produce disturbing physiological ef `resultant loss of oxygen transport. fects when' excessive concentrations are '^ Of the nitrogen-containing salts,_the ni present in the inspired air. trates and nitrites cause physiological dis- turbances. The cyanides, which are included Industrial poisons . here because of their nitrogen content, are (Organic compounds) ; widely'used in plating and metal treating. They are extremely toxic, especially in contact with acid, when they form hydrogen [^cyanide. Cyanogen, used for fumigation, is also dangerous. r Acid gases (chlorine, brom ineiodine, 1 hydrogen fluoride, hydrogen chloride, suli fur dioxide, hydrogen sulfide, oxides o f ni, trogen and phosgene ) have in some instances been referred to elsewhere in the manual.* i'jpS 1 f See "Part VII " ChemicarHazards.' Aliphatic hydrocarbons. Of this group, the compounds most common to industrial use are the gasolines, naphthas, benzine, kerosene, fuel and lubricating ails. They have wide application, being used as sol vents, cleaners, degreasers and as vehicles in paints. Their vapors will produce headache, diz ziness, nausea, vomiting, stupor and un consciousness. They act as irritants to the skin and are common causes of industrial m J s i