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FILE NAME: National Safety Council (NSC) DATE: 1964 DOC#: NSC122 DOCUMENT DESCRIPTION: NSC - Accident Prevention Manual for Industrial Operations - 5th Edition tr : IA[* rAL A .-x iV CO U KCiL 111 , *..vc- ,y \ , v c. MANUAL A CC I DE N T , L bi43-32l PREVENTION for Industrial Operations / f Q> c f #P R 0 2 1993 EDITION NATIONAL SAFETY COUNCIL Chicago, Illinois 60611 y i 121.35 EFACE ffhe dominant theme of this Manual is safety; the pervading purpose is accident vent ion. Industrial accident prevention has as its primary objective the preven ts injuries to persons; an auxiliary goal is the prevention of damage to equip811 and other property. The favorable reception of the first four editions of this book by safety engineers ^rVfihd others who have the responsibility for accident prevention has provided the incentive for this revised Fifth Edition. The object was to update the material and extend its scope while being more ftjxnific in both word and illustration to reduce the bulk of the book. For improved readability, a slightly larger and clearer typeface has been used. For easier refer- the index includes as many synonyms as possible, but it has been consider ably .shortened by including only major references under each subject. If a subject I# discussed on successive pages, only the first page is referenced. | Two new chapters have been developed: "Audio-Visual Aids" and "Industrial 1 Noise." Many others have been completely revised. For more logical organization, -'as ipne chapters have been retitled and material has often been regrouped. I Some duplications will be found among the sections. The Editors think this flidlitntes the use of a section and avoids the necessity for frequent reference to v t har parts of the book. Where a significant amount of additional information is another chapter, cross references are provided. The preparation of each chapter was directed by a National Safety Council staff *)>i <lalist in the field. In some cases, new material was developed b y recognized nlithorities who are identified by the footnote on the first page of each chapter. Ill worked with many collaborators. For all of these men, the most satisfying itward is the knowledge that they have contributed to the more effective per formance of the industrial safety men of today, and to the education of future kAiSpiiretly men. , | To increase the effectiveness of those responsible for industrial accident pre. vention, much detailed material had to be included, but it is not the purpose of fill Manual to serve as a complete handbook of all design, fabrication, operation, S|>spection, and management principles. Rather, it attempts to set forth the Important points to be considered when evaluating an industrial accident prevention ogram including the safe operation of equipment and processes. If This Manual does not constitute an official code or standard, and it does not viate prescribed regulations or minimum safe practices. When practices are escribed, it is not intended that they supplant other practices that have proven tMactory, nor is their description intended to discourage innovation and original ly in contributing to ever-more-effective industrial accident prevention. No one prescribed safety formula can be superimposed on all accident-prevention irograms. As a suggestive guide the Manual necessarily speaks in broad and gen 'd1 terms; its contents must be adapted to the specific circumstances of the parcular operation. Ultimate responsibility, therefore, must rest in the selection of the hnique or method for correcting any given condition or situation. T h e E ditors w INDUSTRIAL h y g i e n e Free silica is uncombined silicon dioxide The fine airborne fibers o f asbesln (SiOs). Silicates contain silicon and oxy* pass through the upper respiratory i n.' gen combined with other elements in more the lower parts of the lungs t:o cause n,.- complex molecules. The SiOs reported in tion and to form "asbestos bodies" a 1, chemical analyses for mineral and geological the fibers are encapsulated. This <liii reports is the total of the silicon dioxide fibrosis probably begins as a "collar" .1 ! present, both the free silica (if present), the terminal bronchioles. There is evi.i and the silica combined in the mineral. Such that other minerals having a fibrous cl.... analyses are not reliable indications of the ter (except glass fiber) can produce a n silicosis potential of the material, because it tion similar to that of asbestos. is the uncombined or free silica that is most Following a study by th e U.S. I n1 important in industrial dust exposure. So that an exposure can be properly evaluated, the percentage of uncombined silica must be determined by petrographic analysis using a polarizing microscope or, preferably, by X-ray diffraction analyses and special ana lytical chemical procedures. Health Service of the asbestos textile ini try," it was recommended that the dust . centration be kept at less than 5 mpi>< l prevent asbestosis. Evaluation of an ( sure to asbestos dust is based on the / amount of dust, since the concentration injurious fibers will be kept within There has been some experimental evi dence that some dusts may tend to inhibit limits if the fine dust is kept below suggested threshold limit. the action of silica on the body, but this in hibiting action is so slight and uncertain that it must be discounted in practice. In fact, there is also evidence that the nonsiliceous components of a dust mixture containing free silica may provoke a disabling condition more severe than that caused by the silica acting alone. Miscellaneous pneumoconioses. E \ though a dust is classified as harm), amounts above the TLV can lead to tnml.' by causing a pneumoconiosis, mechanic V irritating the walls of the respiratory -syM. >> or interfering with ordinary lung proem- Mica dust and kaolin dust are two good amples of dusts that ordinarily are c o n M With the exception of asbestos and some ered benign but amounts above the TLV 1: talcs, the silicate dusts do not ordinarily cause a troublesome pneumoconiosis. Mi cause a serious disabling lung condition such as is produced by free silica. Much higher levels of silicate dusts than of free silica dust pneumoconiosis has been observed in grin.! ing operations where mica dust, but no In. silica was present. There were nwl-.-! can be tolerated. In many industries, men changes in the X-ray pictures of the hm have worked with silicate dusts that con and some disability. The cases occmn-' tained no free silica without development of where the dust exposures were massive o< disability or of nodulation in the lungs. Tire many years. h X-ray may show shadows indicating dust deposits in the lungs, but the pneumoconiosis Toxic dusts and fumes ! is essentially harmless. However, partially Systemic reactions are caused by in-. disabling pneumoconioses have been reported dusts and fumes of various elements .... where men have worked for long periods of their compounds and by certain organic c o n . time in very high concentrations of certain pounds. All metallic fumes are irritating. . silicate dusts. Disabling pneumoconioses pecially when freshly generated. IndustrieH from exposure to abnormally high concen important metals and their compounds lli.u trations of mica, tremolite talc, and kaolin can have a toxic effect when the dust ... dusts have been described in the literature. fumes are inhaled include arsenic, antimnw The clinical signs are not the same for these cadmium, chromium, lead, manganese, him silicate dusts as for free silica, but the symp cury, selenium, tellurium, thallium, uranium toms can be marked. and a few others. Asbestosis. Several minerals having a fibrous character are classed as "asbestos"-- hydrated silicates of magnesium with vari able amounts of iron, calcium, sodium, potas sium, and aluminum present as impurities. U.S. Public health Service, .Washington D.C. "A Study of Asbestosis in the Asbssin Textile Industry." Bulletin No. 241. 1938. 39-8 INDUSTRIAL HYGIENE stos can be effect of some metals, such as mag ly generated fumes of metals such as zinc, ! tract in nesium and zinc, appears to be transient. magnesium or their oxides. Symptoms ap jse irrila- 1inly limited data are available on the exotic pear from 4 to 12 hr after exposure and is" whi'ic rare earth metals. consist of fever and shaking chills. There is is diffusiar" a lv in i : evidenci as chara ice a renc- .S. Puliti.- Although the dusts and fumes from metals u-ilh low toxicity do not need as much attenfion as the dusts and fumes from highly >xic metals, they should not be neglected or isregarded. The metals with low toxicity un', more readily controlled because greater ,imounts can be tolerated, but their dusts complete recovery usually within one day, and ordinarily the employee can return to the same job without recurrence. However, after a period in which there has been no contact with the fume, for example, after a layoff, resumption of exposure is likely to bring on an attack. tile in(ins md fumes should be kept at reasonable Metal fume fever is caused by heavy con i dust con levels since excessive amounts of any of centrations of fumes. Zinc oxide fume is the j mppcf in diem can be harmful. most common source, but cases caused by : : an expo i the tnlnl atra don ni fithin sali- below lIti- Inhalation of the dust of lead compounds i-, (he most common mode of entry of lead min the system, and ingestion of lead com pounds can add to the problem if personal hygiene is poor. Workers therefore should be the inhalation of fumes from magnesium oxide, copper oxide, and other metallic ox ides have also been reported. The condition does not occur from the handling of these oxides in powder form. Apparently, it re -ucouraged to wash thoroughly before eat sults only from the inhalation of extremely E v i n i i harmless, 1 to trouble lechanicalk- ' i system, processes, /o good <v are con-siil ne TLV cm, liosis. Mira sd in grimi but no free ere marked jf the lungs es occurred massive over ing, and lunchrooms should he apart from work areas. Lead is a normal constituent of plants and nnimals, and people ingest and excrete it daily even though they are not exposed to lead in their daily work. When intake rates exceed the normal excretion rates, however, li-ad builds up in the body. When the accu mulation reaches a sufficient level, symptoms f poisoning or intoxication appear. The concentration of airborne lead should itherelore be kept below the threshold limit be cause of lead's high toxicity and its tendency in accumulate in the human system. Beryllium intoxication is a severe system ic disease that can result from the inhalation fine particles freshly formed as fume (called a 'nascent fume" ). Cadmium, mercury, and other metals may also produce a fever fol lowed by the toxic effects of the element. Organic Solvents The widespread industrial use of organic solvents presents a major problem to the in dustrial hygienist, the safety engineer, and others charged with the responsibility for maintaining a safe, healthful working en vironment. Getting the job done without hazard to employees or property is depend ent upon the proper selection, application, handling and control of solvents and an un derstanding of their properties. ed by toxic lements ami organic com irritating, es . Industrially npounds timi the dust in lie, antimonv, iganese, niernm, uranium, of the dust or fume of metallic beryllium, beryllium oxide, and soluble beryllium com pounds. (There is no evidence of intoxicalion from the ingestion of insoluble com pounds.) Only the inhalation of the beryl lium-bearing dusts or fumes produces syslemic disease. Accordingly, control of such dusts and fumes to keep them below the concentration specified by ACGIH (Ameri can Conference of Governmental Industrial Hygienists) threshold limit values is a basic protective measure. When the soluble salts of beryllium, espe cially beryllium flouride, contact cuts or abrasions on the skin, deep ulcers may be formed which heal very slowly, and com Labeling The labeling of solvents to indicate their properties and health and fire hazards is an extremely important method for recognizing and evaluating the hazards. In fact, if a sol vent is not properly labeled, it should not be used. The purchasing department can great ly help the safety department by notifying suppliers that only properly labeled solvents will be accepted in the plant. Uniformity in language and layout is de sirable to simplify understanding of solvent use. The MCA's Guide to Precautionary Labeling of Hazardous Chemicals, Manual L-l, recommends the following subject mat- plete surgical excision of the ulcer is some , Washington, times required to effect healing. i the Asbestos 241. 1938. Metal fume fever is an acute condition caused by a brief high exposure to the fresh Manufacturing Chemists Assn., 1825 Connecticut Ave. NW., Washington, D.C. 39-9 'NDUSfimFti 'tii&tENE Alcohols Aldehydes and- ketones -Glycols and glycol ethers sAromatic '; hydrocarbons Aliphatic hydrocarbons Halogenated ' / hydrocarbons Esters -Ethyl alcohol ^ Acetone *" -,s ` Cellosolve ' < Toluene 4 > -1 Q 1 Mineral spirits' A^ feij> * ` /' "Methyi chloroform Ethyl acetate SOLVENTS, --------------------Chemical Formula o CHUCHsOH'' ; | (CHa)SCO; , iK lillfpSiltlifjf CaH.0 ( CHi).OH-i s iiliiilp iiiS S CaHiCHs * i Mixture of paraffins and cycloparaffins )V- CHaCCla"* CHaGOOCsHa ' ter and organization: A L Name of product. 2. Signal word designating degree of hazard--DANGER! WARNING! or CAU TION! POISON and the skull-andcrosshones should he used for chem icals defined as poisons or required 1 by law to be labeled as such. POISON - should be used in addition to the other ' *" signal words. 3. Statement of hazards (EXTREMELY HAZARDOUS, FLAMMABLE). 4. Precautionary measures to be taken or action to be avoided (avoid breathing vapor, keep away from heat or open flame). 5. Instructions in case of contact or expo sure (flush eyes or skin with plenty of water for at least 15 min.). 6. POISON legend, followedi by first-aid instructions or antidote.1 , General^ physiological effects ways be a much greater inhalation hazard Inhalation of excessive amounts of solvi vapors may produce various physiologic effects. In some instances, it may result; impairments, such as lack of eoqrdinatio drowsiness, and -similar symptoms that im lead to increased accident proneness. Oth effects may include damage of. the,..bloo lungs, liver, kidney, gastrointestinal -systo' and other critical organs or tissues. Some generalizations nan be, made lot cerning the physiological effects of .each olftof organic solvent shown m Table however, specific details for mdmduaLidj vents are given in Chapter 40, IndustrU Alcohols aTe generally anesthetic; irrltffl ing to the eyes and upper respiratory tragi and - may possess other toxic properti^ Their toxicity increases and v o l a t i h M | creases with increasing molecular'weights Tlooxxic concueenuturaautiuoinios of alco-h-o--l, vap*or, s , ^ mists ihave ciha_r_a-ictfetrrtinsTtfiec AoTdWorisrirantnndr-irrimj Physiological effects from industrial or ganic solvent exposures come principally from skin contact and inhalation of the vapors. Ingestion with resultant absorption into the digestive tract is not normally con sidered an exposure hazard in industry, it the solvent is present in such amounts that ingestion becomes a hazard, there 'Will al- 3 Aldehydes:and ketones, as a rffie,'_arehoL irritant and narcotic,^ with the action predominating in the aldehydes, -a the narcotic action being the prime_hazajgj in the ketones.' .High concentrations^(L either can be identified by odor and lmtgnj effect. ' `v 39-10 ELEMENTS F INDUSTRIAL* TOXICOLOGY in the handling of wet dross from a light metals plant, in the cleaning -of tank cars which .have held sulfuric and hydrochloric acids, .in the cleaning of pipes with an acid contaminated with arsenic, in the precipita tion of cadmium with metallic zinc, and in other operations. . , .. Arsine rapidly destroys the red cells. After it -has been inhaled,-the first.signs are those of lack of oxygen. After some time the body .begins to excrete the damaged red cells; which appear as a dark or-bloody urine. The kidneys may then become too clogged to operate at all.s Arsine, in very small amounts, is also capable of producing a chronic type of poisoning, but it is -more typically a source of acute episodes. The possibility of arsine formation should always be considered when there-is freshly formed hydrogen around ores of-the heavy metals, since arsenic is widely distributed in small amounts and only a trace of it is re quired to produce enough arsine to be trou blesome. - ' 'One of the more common sources of arsine incidents in recent years has been the han dling of dross from the aluminum refining of metals. Probably the most significant ob servation about these cases, aside from the fact that the moisture dn the atmosphere is enough to form arsine, is the fact that the peopleinvolved in them have not been aware of the garlic-like odor which'is supposed to be a warning of the presence of arsine. See Hygienic Guide. ' - ' Asbestos is a hydrated magnesium' silicate found in the minerals chrysotile, amianthus, actinolite, and tremolite. -Practically all- 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 and1 advances slowly and is equally resistant to treatment. There is also good evidence that inhaled asbestos causes lung cancer, ' 1\ See-Hygienic Guide. 40-18 ' Barium, in the form of its soluble-.sal toxic on both ingestion .and inhalations highly caustic when applied to the skin/t carbonate and sulfide are sufficiently sditi1 to he toxic, although not very caustic/ sulfate, which is used as a contrast mdi in X-ray work,' is too insoluble to'showl toxicity, ' and -soluble sulfates ar/sp antidotes for ingested barium salts. Since these salts'produce violent stmtl tion of all muscle, upon ingestion (they.'! duce severe disturbances of th"-digest system'/After absorption, the barium increase blood pressure by constriction the arterial muscle, "slow down heart'*,! by'an action similar to that of digitalis;1a`l first excite and then paralyze^ the cerffi nervous system. In spite of the high Iin-4h*tf ent toxicity, there are few cases of inclu trial poisoning with barium. Barium is a heavy metal, and the dujj/ the insoluble salts will collect in the 'lu and give rise to the condition known baritosis. Its nodular appearance on X-ri film may be mistaken for that of silicosi Men showing the sign of haritosis are parently not disabled or inconvenienced t anyway. See'Hygienlc Guide. Benzene (benzol) is a colorless, flanirii ble, volatile liquid with a rather pleasii a aromatic odor. Its fire hazard is' betw1 ethyl alcohol and ethyl ether.- The great hazard is that of chronic poisoning by'll halation of comparatively- small , ambu: over a long period of time.- It is one of if two - or three most" dangerous -organic soli vents in commercial use, and acts prima on the blood-forming organs, producing 4 vere anemia, bleeding'under the sldn, l great reduction in the ability of die blood| clot. The most convenient measurement / damage is given by a blood county who may be exposed to benzene va should have blood counts at regular int vals and significant ,,changes in the ocour should be closely investigated. iivjUJ9S Headaches, dizziness, fatigue, loss of-a l petit, irritability,- nervousness,- noseble" and other- signs of abnormalities^of blood may or may -not be -present in chroni poisoning/. A single heavy exposure to benzene vi may produce a serious acute effect, Iti desi a d 'installation"of `,lv VIve m e d is c rim in a tio n o f fin e d e t . - ________ eye Protection. As far as possible, it 1uffic` o ! ^ n t akrf^h ^fTTbhe s p e c u la r s u r f a c e o f tbh e m a te r ia ], m a v ,, Z ,, reflected ^g la r e w e l l ", t i ? d ire <=tOn o f lig h t, d iffu s io n , I n d f i SSop -eec iia. tl U*bUM ~eb H s rb ti_c__a____e__u__cVh H I?' U s.a...s........<.....5.....,......-..-...-..-..-..-..-..----- -22 ^nneeCc ees5sSi,tUa ttee sEpPeecCiiea)) consideration in s-feelceticotns - , ____ . ____ ViU"stJBe*sO-.-T'--,"._'r.--.._.__.,__-4_7fe*ar*o*r*n*e*mmatmmO-mim* *M--v*---.--cr- .--. - ,: " w v v t --~--. v _ . J?m'*r-*TrS* --- - . aa-staad4ta. p s * (S e- *i,A -Jfcet -ifi- . H dplacem ent r f * h t . ,, equipm ent, or orientation of tbe .o r b . f-i 1- i :rt' ? S T E T ? E N G I N E E R I N G .. T A B L E S 45-21 TABLE 45-H. A GUIDE TO VENTILATION RATES FOR TYPICAL INDUSTRIAL EQUIPMENT State or Local Regulations Should Be Consulted and Followed W here Higher Ventilation Rates Are Specified Operation Type of Hood Ventilation Air Flow Usual Transport Velocity (fpm) Remarks and References Abrasive blast rooms (sand, grit, or shot) Tight enclosure with air i n l e t s (usually in roof) 60-100 fpm d ow n d raft (long rooms of tunnel proportions 100 fpm crossdraft) 3,500 Ref. 8. Many codes specify mini mum downdraft of 80 fpm Abrasive blast cabinets Tight enclosure with access open ings 20 air changes per minute but not less than 500 fpm through all openings 3,500 Ref. 14 Asbestos Carding Spool winding Enclosure Local hoods 800 cfm per machine 50 cfm per spool 3.000 3.000 Ref. 2, 16, 17. See references for details and other operations Bagging Open bag top Booth or enclosure (provide spillage hopper) Paper bags--100 cfm per sq. ft. open area Cloth bags--200 cfm per sq. ft. open area 3.500 3.500 Ref. 18 Barrels--Drum s (filling or removing material by scoop) Local hood Booth 100 cfm/sq. ft. of container cross section 100 fpm at face 3.500 3.500 Ref. 15, 19. Hood with 1-in. slot extending 120 to 180 deg con tainer. Does not confine spillage. Confine s p i 11 a g e--also recom mended for container upsetting. Belt conveyors 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 3,500 Ref. 18, 20. Bins (closed top) Connect to bin top away from feed point 150-200 fpm through open area at feed points 3,500 Ref. 19, 20 Bucket elevators Tight c a s i n g re 10 cfm per sq. ft. of elevator cas quired ing cross-section 3,500 Ref. 19 41-4 TABLE OF CHE MI CA L H A Z A R D S ') ') ') Substance ammonia amyl acetate--n amyl alcohol--iso amyl alcohol--n aniline antimony (salts) arsenic arsine * asbestos Flash point F. TABLE OF CHEMICAL HAZARDS--Continued Explosive limits % by volume Autoignition temperature 0 F. Maximum acceptable concentration for Usual mode of 8-hr. exposure entrance to body Signs and symptoms of poisoning Lower Upper gas 16 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- " 200 p.p.m.3" inhalation Irritation of eyes and respiratory tract, headache and d i z z i n e s s , cough, nausea. 109 1.2 . . . 650 100 p.p.m." inhalation Same as amyl acetate. 100 1.2 *, . 700 100 p.p.ro.s 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.3S 0.15 mg/cu.m.6 0.5 mg/cu.m.3" 1 p.p.m.s 0.05 p.p.m.3" 5 m.p.p.c.f.1 inhalation of dust, ingestion Acute; vomiting, colic, diarrhea, irritation of mouth and throat. Chronic: indigestion, loss of weight and appetite, s o m e t i m e s severe dermatitis. inhalation of Irritation of skin, loss of hair and dust, ingestion nails, perforation of nasal septum, and direcr action hoarse voice, cough, n e u r a l g i c on skin and pains, diarrhea. mucous membrane inhalation . Headache, nausea, vomiting, chills and shivering, jaundice, dark or bloody urine. inhalation Chronic: shortness o f breath, as bestos corns. TABLE OF CHEMICAL HAZARDS--Continued Auto- . Ignition M'-dmum acceptable ( unperature c:eniration for Usual * mode of * ' Signs and symptoms (. TABLE OF CHEMI CA L HAZARDS 41-6 Substance j arsenic jj ; arsine | asbestos j barium j benzene i benzoyl chloride j benzoyl peroxide j benzyl | duorida s|Pfi j bromine j bromochloro! methane [ (^ethylene obromide ) Flash Point (deg F) -- TABLE OF CHEMICAL HAZARDS ( continued) Flammable cr Explosive Limits (%by volume) Lower Upper Autoignition Temp. (deg F) Boiling Point (deg F) Vapor Volume (cu ft) pergal) Evaporation Rate (E th e r^ l) * -- -- -- 1,139 -- -- NSC Data Sheet 499 References MCA Data Sheet ACSC Bulletin AIHA Hygienic Guidet SD-60 12-58 gas -- -- -- -67 -- -- 6-56 -- nonflammable -- -- -- -- 4-58 element ignites spontaneously with moisture, and peroxide, chlorate, and -- -- -- nitrate react violently with flam mable materials 12 1.4 7.1 1044 176 37 2.8 12-62 308 SD-2 C-77 12-61 162 -- -- -- 387 28 103 -- -- -- -- decomposes - at 250 F -- W-; - SD-81 153 1.1 - 1085 354 28 47.8 SD-69 jS3^i.s0!M5 ...rir -- nonflammable - J "T ' , - 138 - - ! 313 SD-49 C-49 8-58 -- nonflammable - 154 - - 12-61