Document nm5YN6RmoZXpr11OvbMMB4zRw

 Wm f "V* -- iVM i f^j:\ 4 i .: 1U i , i J ACCIDENT - :fll|l| .-Ssgsssffj'V-"'JliftiS? PREVENTION ^ MAN UAL for Industrial Operations / Y6 tf ^pH 1i -0 ^01j EDITION NATIONAL SAFETY COUNCIL Chicago, Illinois 6061 1 o/d? APR 0 2 \m PREFACE SlWv'Tlie dominant theme of this Manual is safety; the pervading purpose is accident y;;B|>ffivt-fi;ii)n. Industrial accident prevention has as its primary objective the preven_ -tftiu of injuries to persons; an auxiliary goal is the prevention of damage to equip"fVAlftriH nnd other property. ~lpPfI''.Thc favorable reception of the first four editions of this book by safety engineers others who have the responsibility for accident prevention has provided the = p jhf'nnlivc for this revised Fifth Edition. figyy `Hie object was to update the material and extend its scope while being more JliSSSj'HH'ific 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 referSflBWce, the index includes as many synonyms as possible, but it has been considerapSitbly .shortened by including only major references under each subject. If a subject discussed on successive pages, only the first page is referenced. Two new chapters have been developed: "Audio-Visual .Aids" and "Industrial IpgVNfjj.se." Many others have been completely revised. For more logical organization, -TA-Some chapters have been retitled and material has often been regrouped. VA Some duplications wall be found among the sections. The Editors think this . _ ..facilitates the use of a section and avoids the necessity for frequent reference to -A oilier parts of the book. Where a significant amount of additional information is V in niiother chapter, cross references are provided. The preparation of each chapter was directed by a National Safety Council staff A . specialist in the field. In some cases, new material was developed by recognized f _ Authorities who are identified by the footnote on the first page of each chapter. fgypAl! worked with many collaborators. For all of these men, the most satisfying rr-ward is the knowledge that they have contributed to the more effective per - Tlonnance of the industrial safety men of today, and to the education of future M'Asaifcty men. To increase the effectiveness of those responsible for industrial accident pre-%-Vrntion, much detailed material had to be included, but it is not the purpose of iSgphis Manual to serve as a complete handbook of all design, fabrication, operation, L~Spm!,ection, and management principles. Rather, it attempts to set forth the w~iniportant points to be considered when evaluating an industrial accident prevention i:Si||>roKram including the safe operation of equipment and processes, ty This Manual does not constitute an official code or standard, and it does not -:>9>l->vinte prescribed regulations or minimum safe practices. When practices are fjgj|b.s'cribed, it is not intended that they supplant other practices that have proven -Wlisfactory, nor is their description intended to discourage innovation and originalIBity in contributing to ever-more-effective industrial accident prevention. No one prescribed safety formula can be superimposed on all accident-prevention MjFfrograms. As a suggestive guide the Manual necessarily speaks in broad and gen- terms; its contents must be adapted to the specific circumstances of the par~3yfcular operation. Ultimate responsibility, therefore, must rest in the selection of the ifjjglechnique or method for correcting any given condition or situation. The Editors INDUSTRIAL HYGIENE Free silica is uncombined silicon dioxide {SiOa). Silicates contain silicon and oxy gen combined with other elements in more complex molecules. The SiO reported in chemical analyses for mineral and geological reports is the total of the silicon dioxide present, both the free silica (if present), and the silica combined in the mineral. Such analyses are not reliable indications of the silicosis potential of the material, because it is the uncombined or free silica that is most 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. There has been some experimental evi dence that some dusts may tend to inhibit 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. With the exception of asbestos and some talcs, the silicate dusts do not ordinarily cause a serious disabling lung condition such as is produced by free silica. Much higher levels of silicate dusts than of free silica dust can be tolerated. In many industries, men have worked with silicate dusts that con tained no free silica without development of disability or or nodulntion in the lungs. The X-ray may show shadows indicating dust deposits in the lungs, but the pneumoconiosis is essentially harmless. However, partiallydisabling pneumoconioses have been reported where men have worked for long periods of time in very high concentrations of certain silicate dusts. Disabling pneumoconioses from exposure to abnormally high concen trations of mica, tremolite talc, and kaolin dusts have been described in the literature. The clinical signs are not the same for these silicate dusts as for free silica, but the symp toms can be marked. The fine airborne fibers of asbesm pass through the upper respiratory the lower parts of the lungs to cause tion and to form "asbestos bodies" -' the fibers are encapsulated. This e. . fibrosis probably begins as a "collar" the terminal bronchioles. There is evt that other minerals having a fibrous i ter (except glass fiber) can produce a tion similar to that of asbestos. Following a study by the U.S. i Health Service of the asbestos textile try-,0 it was recommended that the dusi centration be kept at less than 5 mpo prevent asbestosis. Evaluation of an sure to asbestos dust is based on the amount of dust, since the concentra'i. injurious fibers will be kept within limits if the fine dust is kept belov suggested threshold limit. Miscellaneous pneumoconioses. F though a dust is classified as ham amounts above the TLV can lead to tm by causing a pneumoconiosis, mechani irritating the walls of the respiratory- s> or interfering with ordinary lung procMica dust and kaolin dust are two goof amples of dusts that ordinarily are co: ered benign but amounts above the TLA cause a troublesome pneumoconiosis. ' pneumoconiosis has been observed in `.a ing operations where mica dust, but no silica was present There were ma; changes in the X-ray pictures of the X and some disability. The cases ocem where the dust exposures were massive many years. Toxic dusts and fumes Systemic reactions are caused by ; dusts and fumes of various elements their compounds and by certain organic ; pounds. All metallic fumes are irritating, pecially when freshly generated. Industrio important metals and their compounds f can have a toxic enect when the das: fumes are inhaled include arsenic, aniinu cadmium, chromium, lead, manganese, :> cury, selenium, tellurium, thallium, uranic 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, Washings. D.C. "A Study of Asbestosis in the Ashes Textile Industry-." Bulletin No. 241. 1933. 39-S INDUSTRIAL HYGIENE JStOS The effect of some metals, such as mag- ly generated fumes of metals such as zinc, tract ' m-sinm and zinc, appears to be transient. magnesium or their oxides. Symptoms ap ase irrii.i- 1 wiy limited data are available on the exotic pear from 4 to 12 hr after exposure and s" wlii-i" *mi rare earth metals. consist of fever and shaking chills. There is is diffs; ar" ah'mi eviden: - as char.,: ce a rear- .s. Pul.;.. Although the dusts and fumes from metals A-ch low toxicity' do not need as much attenomi as the dusts and fumes from highly 'mxic metals, they should not be neglected or disregarded. The metals with low toxicity more readily- controlled because greater nnonnts 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 indn- Hid fumes should be kept at reasonable Metal fume fever is caused by heavy con dust Cor. Tvels since excessive amounts of any of centrations of fumes. Zinc oxide fume is the mppcf ;< dn-m can be harmful. most common source, but cases caused by an expn i the to-:..i atration dthin s.-i-ibelow ; i . E v . i. harmlr-N. 1 to troni.teehanicT - SVSCC; . ^races.s^ SO good r:, are consul ne TLV cr,r, :iosis. Md> ed in grim! but no ireere maria-d >f the lime es occurn massive ovm Inhalation of the dust of lead compounds the inhalation of fumes from magnesium i the most common mode of entry of lead oxide, copper oxide, and other metallic ox the system, and ingestion of lead com- ides have also been reported. The condition .iminds can add to the problem if personal does not occur from the handling of these !i->diene is poor. Workers therefore should be oxides in powder form. Apparently, it re ncouraged to wash thoroughly before eat sults only from the inhalation of extremely ing. and lunchrooms should be apart from fine particles freshly formed as fume (called I -A iirk areas. a ` nascent fume"). Cadmium, mercury, and } Lead is a normal constituent of plants and nnimals, and people ingest and excrete it other metals may also produce a fever fol lowed by the toxic effects of the element. daily even though they are not exposed to ii-iid in their daily work. When intake rates i-vceed the normal excretion rates, however, Tad builds up in the body. When the accu mulation reaches a sufficient level, symptoms ;.f poisoning or intoxication appear. The i -mcentration of airborne lead should theremre be kept below the threshold limit bei- iiiise of lead's high toxicity' and its tendency in accumulate in the human system. Beryllium intoxication is a severe systemH- disease that can result from the inhalation 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. eel by to\ Iements ami organic com irritating, c . Industria':npounds ih.ii the dust -a tic, antimom. iganese, iro runi, uranium. "f the dust or fume of metallic beryllium, beryllium oxide, and soluble beryllium com pounds. (There is no evidence of intoxicaTon from the ingestion of insoluble com pounds. ) Only the inhalation of the beryl lium-bearing dusts or fumes produces sysii- inic disease. Accordingly, control of such dusts and fumes to keep them below the oncentration specified by ACGIH (Ameri--an 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,a recommends the following subject mnt- plete surgical excision of the ulcer is some , Washington. times required to effect healing. 1 the Asbestos Metal fume fever is an acute condition Manufacturing Chemists Assn., 1S25 241. 193S. caused by a brief high exposure to the fresh Connecticut Ave. NW,, Washington, D.C. 39-9 1NI)U STRIAE HYGIENE - : TABLEV39-B . -' . .. MAJOR CLASSES OF COMMON ORGANIC SOLVENTS - . Class - - - Typical-Example . - Alcohols .. Ethyl alcohol ' - - Aldehydes and - -. Acetone : ketones ..... . - Glycols and - glycol ethers. Cellosolve - . Aromatic w' .'Toluene - hydrocarbons -" Aliphatic^ ; hydrocarbons1 ' Mineral spirits' - . Halogenated . hydrocarbons ' Methyl chloroform Esters .. . . . Ethyl acetate . . Chemical Formula '.>Sf , CH.CHiOH- '1 ' ^ - (CHa)2CO, ., a C2HsO(CHi)2OH CoHsCHs - . .- i a . (Mixture' of paraffins ?3 and cycloparaffins) ' ` cacch '"5| .. CILCOOCTL ". ter and organization: ways be a much greater inhalation hazard,riff! 1. Name of product. - . . .Inhalation of excessive amounts of solvculll 2. Signal word designating degree of haz ard--DANGER! WARNING! or CAU TION! POISON and the skull-and- ' crossbones should be used for chem' deals- defined as poisons or required ' by law to be labeled as such. POISON; should be used in addition to the other - signal words. -vapors may produce- various physiologic^^ effects. In some instances, it may result ifi impairments, such as lack of coordination^ drowsiness, and similar symptoms that mapj lead to increased accident proneness. Otbei|| effects may include damage of: the. bboa*. lungs, liver,.kidney, gastrointestinal systerng and other critical organs or tissues.; 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). - -- 'T . Some generalizations can be. made conjp_ .ceming the physiological effects of each ciagfj|| "of organic: solvent. shown in Table. 39-BJjT' however, - specific details for individual solri|U vents are given in Chapter 40, Toxicology." , 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, followed by first-aid instructions or antidote.' ; General physiological effects 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. ` If the solvent is present in such amounts that ingestion becomes a hazard, there will al- ' Alcohols are generally anesthetic, irrituf ^ ing to the eyes and upper respiratory' trac|f| and may possess other toxic' propertio*gjgg Their toxicity - increases , and -volatility djfil creases with" increasing molecular' weig Toxic concentrations of alcohol vapors mists have Characteristic- odors: and-r irritaai^| effects. - - - - -- ;: : ' Aldehydes and ketones, as a rule, an _ irritant and - narcotic, with the irritatihg^S action predominating in the aldehydes, and<|| the narcotic action being the prime hazardjf in the ketones. Vi'High concentrations either can be-identified-by odor and irritant . -. : f|j 39-10 - - ELEMENTS' OF 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 bodybegins 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. 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 heavymetals, 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 in the 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. - See Hygienic Guide. Asbestos is a hydrated magnesiuiri 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-and- advances slowly and. is equally resistant to treatment.. There is also good evidence that, inhaled, asbestos causes lung; cancer. . See Hygienic Guide. Barium, in the form of its soluble snlt^'j toxic on both ingestion and inhalation an highly caustic when applied to the skin. T1 carbonate and sulfide are sufficiently solul; to be toxic, although not very caustic, T! sulfate, which is used as a contrast medlij in X-ray work, is too insoluble to show-SliiM toxicity, and soluble sulfates - are- specif] antidotes for ingested barium salts. - Since these salts produce violent stimif58jj tion of all muscle, upon ingestion they, pf __ duce severe disturbances of the' digestif system." After absorption, the barium increase blood pressure, .by constriction the arterial muscle, slow down heart' haffljjli by an action similar to that of digitalis,ripll|| first excite and then paralyze the ceritfi|fj|| nervous system. In spite of the high inhepjySI ent toxicity, there are few cases of indtiK-uif trial poisoning with barium. ' Barium is a heavy metal, and the dust ;|jj|| the insoluble salts will collect in the lunftiJl and give rise to the condition known baritosis. Its nodular appearance on X-raJfepfl film may be mistaken for that of sflicoli|p| Men showing the sign of baritosis are nj>* -p parently not disabled or inconvenienced ia Zi any way. ' See Hygienic Guide. Benzene (benzol) is a colorless, ble, volatile liquid with a rather pleasaflfjjlf aromatic odor. Its fire hazard is;'betweifijj ethyl alcohol and ethyl ether;~The greatoj|j hazard is that of . chronic poisoning, by in|i halation of comparatively; small aroourijil| over a long period of time. It is one two or three most dangerous- organic soli vents in commercial use, and acts primarily on the blood-forming organs, producing-SfiL vere anemia, bleeding under the skin, and great reduction in the ability of the blood tOj| clot. ''' The most convenient measurement ^ damage is given by a blood count.;, Peopl|ij| who- 'may be exposed to benzene vaPCj^m should have blood counts at regular intaifgll vals and significant; changes-in the countfjj should be closely investigated. ;. - Headaches, dizziness,. fatigue, loss of af|| petite, irritability, nervousness, nosebleeagjl and . other signs- of abnormalities , of . thfjjl blood may or may not be present in chronfl|j| poisoning. - -. ' - - ; A single heavy exposure to benzene vapSgl may produce a serious -acute effect, simil; 40-18 ' DGY ELEMENTS OF INDUSTRIAL TOXICOLOGY .U soluble salu, 5i id inhalation and 1 to the skin, 'll** ufBciently .s<iiul*i# /ery causlir. Tin* contrast nu-iliitie. uble to show an* ates are sprritw m salts. e violent slinml*igestion they pf of the diyriiiv* the barium sulo y constrict inn H down hear; !><**! t of digitalis. :u4 ilvze the crutiai f the high iniim t cases of im!u* , and the dosi ni lect in the !nng;i dition known at :arance on X-rai that of Silii nsli baritosis arc ap 'nveniencnl in '.olorless, flanmiai rather plensani izard is betwrmt ler. The grcau-ji poisoning by m. small amount! It is one of ;h* ous organic sol. nd acts primni ilv ns, producing = .er the skin, am! :v of the blooii in measurement ol id count. PeopU benzene vnpm at regular intc-p es in the couni d. :igue. loss of ap mess, nosebicisi, rmalities of (U resent in chrmiir benzene vnpoi .te effect, similiii __ an anesthetic with special affinity for the Pfintral nervous system. The first sign is lustily exhilaration, followed by sleepiness, jjixziness, vomiting, trembling, hallucina tes, delirium, and unconsciousness. The main first-aid requirements in acute _ fii.s-oning are removal of the person to fresh jj)r, inhalation of oxygen, and maintenance [ bodily warmth. Skin contact with benzene should be Ivoided, partly because like other powerful ilvents it produces dryness and cracking of ilic skin, but primarily because it will al most certainly involve excessive inhalation I ihe vapor. See Industrial Data Sheet 308 and Hy gienic Guide. Benzene hexachloride--see Hexachlorocyllloliexane. Benzyl chloride is a colorless liquid used jn a variety' of chemical syntheses. Its vaJxir is a potent irritant to the eyes, nose, Rut! throat and may cause lung edema. The plquid may cause severe comeal injury. ItJ. Beryllium. Among the occupational dis|rses produced by beryllium, the first condi tion reported (in 1943) was an acute chemJk'ul pneumonitis, which occurred among porkers exposed to beryllium compounds and was attributed largely to the fluorides. A delayed reaction to beryllium, charac terized as chronic and appearing as late as |iwo or three years after the exposure which caused it, was reported some time later, jlpven more recently, it has been reported Jllint the delay between last exposure to |pK:ryllium and the appearance of symptoms |jnay be as long as ten years. This condition fshowed a granulomatous lesion of the lungs the most striking effect, accompanied by pcneral metabolic disturbances and anemia B"o that the individual had continuous weight loss and great weakness in addition yto a chronic cough. A large number of lenses of dermatitis attributed to beryllium figssnd beryllium compounds have also been re ported. |; Although as recently as 1940 beryllium ||was thought to be reasonably harmless, it Jims since been declared that it is unques tionably a toxic agent and in such small ^.quantities as to be among the most toxic lichemically of all elements yet investigated. i-Aeute effects have been brought about in animals with beryllium in quantities in the order of millimicrograms. Field survey evi dence shows that still smaller quantities may produce the chronic disease in human beings. "Safe" levels of beryllium exposure may ultimately be set well below one ug per cu m of air. It has also been established that a worker may carry- home enough beryllium compound on his clothes to result in illness in some member of his family. Several investigators have demonstrated that the presence of fluorine contributes to toxic action of beryllium. Recommendations issued by the Atomic Energy Commission for the control of beryl lium hazards in atomic energy installations state as follows: 1. The inplant atmospheric concentration of beryllium at beryllium operations should not exceed two ug per cu m as an aver age concentration throughout an eighthour day. 2. Even though the daily average is within the limits of recommendation No. 1, no personnel should be exposed to a concen tration greater than 25 ug per cu m for any period of time, however short. 3. In the neighborhood of an AEC plant handling beryllium compounds, the aver age monthly concentration at the breath ing zone level should not exceed 0.01 ug per cu m. 4. An individual showing any sign of chronic berylliosis should be excluded from further exposure to beryllium com pounds. 5. There is no reason to exclude women from employment in plants handling beryllium. 6. Preemployment and termination exami nations, including chest radiographs, should be required of employees in beryl lium plants. 7. Periodic chest radiographs should be made every six months on personnel ex posed to beryllium. S. Each individual exposed to beryllium should be weighed every two weeks, and if loss of weight is noted the reason for it should be determined. See Hygienic Guide. Boric acid has been used for many years as a mild disinfectant and a soothing and 40-19 SAFETY ENGINEERING TABLES if 45-21 TABLE OE CHEM ICAL HAZARDS (continued) Low er gas TABLE OF CHEMICAL HAZARDS 1 2 -5 8 y < HU .i -a ~ bfl`3 CO 00 in1 in CO r> .3 _y 35 <3 aL, V <! , a3 3C O CO Q CO O a-S Q3 CO 0 Cl CO Cl i-H *H CO 1 Cl rH t> t-i O Cl Q So co CO CO1 CO A Q CO CO & 3* 3 T? 2a1 O * i. 1 1 i &5 <y aS L. flj ^ o R * A 11 1 a 2 a u > >2 3 1 2 .8 co co Cl so . r' g -. a :s*s a o ^ 0 CO pH pH *> CO 1 1 ] ZD rt> CO - , -* 3 a. a tyo < -* 3-. iag -a 2 3 5?> a*o-3* -g3,v5 * a 3 D _ ill? 1 1 1 1 -o ro A 3J 2 5 1 1 ^ sx *"3 --'5 jj 1 g-3 12 *3 5 9, *_s 3 w a.9 10 c T*t O 1--4 1> pH ig n ite s and pc e a c t vi te ria ls * c c c in e i: lo is tu itra te la b le 1 Cl 0css 1 1 i 162 103 1 1 Vi Vr O^ ao 0 in 5^ 1 CO Cl rf . 10 CO in 1 ! 1 1 5 3 17.8 0 V a _a3 ai 41-6 *3 V 'Si *V5 C3 V5 SI 3 b V 03 0 *r* -- X? c 0 N c'-9 N 13 c0 3 0--l >> O OH N 5J * V nC3ii 1 0 iCnO co 01 O a i 0co CO H CO CO CO 6 2~ jo ,,jo p ll