Batch Plant Safety

These handouts and documents with attachments are not final, complete, or definitive instruments. This These handouts and documents with attachments are not final, complete, or definitive instruments. This information is for guidance purposes only. You should independently verify and satisfy yourself as to its information is for guidance purposes only. You should independently verify and satisfy yourself as to its accuracy. The AHBSIF does not assume any liability for damages arising from the use of this information accuracy. The AHBSIF does not assume any liability for damages arising from the use of this information

or exhibits and attachments thereto and renders no opinion that any of the terms, conditions, and/or or exhibits and attachments thereto and renders no opinion that any of the terms, conditions, and/or cited federal standards in this document and the exhibits and attachments should be explicitly followed cited federal standards in this document and the exhibits and attachments should be explicitly followed

by the fund member. Seek specific guidance from the appropriate regulator (OSHA) or professional by the fund member. Seek specific guidance from the appropriate regulator (OSHA) or professional advisor.advisor.

Contents• The following information is to serve as a guide for

creating a comprehensive safety program for batch plant operations.

• This information will address the following:– Dust Exposures– Noise Exposures– Point of Operation/Transmission Guarding– Housekeeping– Maintenance (Lock-out/Tag-out)– Materials Handling– Hazard Communication– Emergency Procedures

Dust Exposure

• Poses a threat to the eyes and lungs.

• Contributes to poor visibility, a common factor in work traffic incidents.

• Typically generated by the following operations:– Machinery working around

stock piles– Cold bin operations– General yard traffic

Noise Exposures

• Prolonged exposure to excessive noise levels associated with the process can contribute to hearing loss.

• Noise is distracting and can interfere with audible communication.

Point of Operation/Transmission Guarding

• All pulleys, belts and drive mechanisms should be covered and protected.

• Moving belts, motors, chain drives, and other forms of transmission potentially accessible to employees must be considered for guarding.

• Loose clothing should never be worn at a plant.

Housekeeping

• Essential for plant safety.

• The yard and any other common traffic paths must be kept free of obstacles.

• Standing water poses potential hazards.

• Power source for all phases of the process must be maintained.

Maintenance (Lock-Out / Tag-Out)

• Manufacturer’s inspection and replacement intervals on all process machinery.

• Power transmission disconnected for all such operations.

• Established Lock-Out/Tag-Out Procedure.

Materials Handling

• Fleet Maintenance– Pre-shift inspection– All safety devices

operational– Maintenance records up

to date and complete

• Operator Training• Traffic Patterns• Bin collection samples

Hazard CommunicationWritten Program

Contains information on how the employer will meet the requirements of the standard

LabelingLabels must include information such as the name of the

material, manufacturer’s name and address, and hazard warnings

(SDS) Safety Data SheetsContain all important information on a material and must be

accessible to employees at any time

Employee TrainingEmployees learn the characteristics of the materials

Written Plan

• A Written Plan must address the following issues;• Procedures• Related Safety & Health

Issues• Training• Chemical Inventory• Labeling Procedures

Labeling – The NFPA Placard

Fire HazardFire Hazard4 – Below 73°F3 – Below 100°F2 – Above 100°F1 – Above 200°F0 – Will Not Burn

Health HazardHealth Hazard4 – Deadly3 – Extremely Dangerous2 – Hazardous1 – Slightly Hazardous0 – Normal Material

ReactivityReactivity4 – Detonate3 – Shock and Heat may

Detonate2 – Violent Chemical Change1 – Unstable if Heated0 - Stable

Specific HazardACID – AcidCOR – CorrosiveOXY - Oxidizer

The placard is used on all storage tanks and transfer containers (gas cans, storage vessels).

3311 22O

LabelingIdentifier 1

Pictograms 2

Signal words 3

Hazard Statement 4

Precautions 5

Supplier Identification 6

Labeling• It is the employer’s responsibility to ensure

that all containers of hazardous substances in the workplace are labeled

• Never remove a label• Container size is irrelevant, all containers

must be labeled• The only labeling exception is “Immediate

Use”, employee has 100% control of material.

Employee Training• Employees must be trained on every new

chemical in which they come in contact• Acute and chronic health effects• Proper handling and use• Proper storage• Clean-Up procedures• Proper disposal• Accessing information (SDS Manual)

Hazard Communication ChecklistInventory of Chemicals Used Match Chemicals With

Exposures

Obtain all SDS Safe Work Practices for Each Chemical

Identify SDS Storage Location Employees Educated on Potential Exposures

Employees Know Location of SDS

Employees Trained on Use of Material

All Containers Labeled Notify Other Contractors When Necessary

Emergency Procedures

• Emergency Evacuation plan

• Fire Safety • Basic First Aid

Are you Prepared?

• Does the facility have a first aid kit?• Are emergency contact numbers readily

available?• Do any of your employees/co-workers

have CPR or First Aid training?• Does the facility have an evacuation

procedure?

Emergency Evacuation Plan

• Employees must be educated on all emergency evacuation plan specifics

• Exit map must be conspicuously posted• Ensure primary and secondary routes are

unobstructed• Assemble outside the facility at pre-determined area

for a head count• Identify who is responsible for head count• Identify who is responsible for emergency power

shut down• Identify who will make appropriate emergency

phone calls• No one reenters facility until emergency is over

Fire Safety

• Good house keeping is key to preventing fires - Do not use compressed air to blow sawdust - Keep evacuation routes/exits clear - Clean up daily

Fire Safety• Develop a system to alert employees in

the event of a fire• Ensure exits are properly marked (steel

roll up doors are not acceptable as fire exits)

• Ensure adequate number of extinguishers for size of building (no more than 75 ft. of travel)

• Ensure employees know extinguisher location

• Train employees on proper operation of extinguishers

Fire Extinguishers• Fire extinguishers must be selected and provided for the

types of materials in areas where they are to be used• Class A, Ordinary combustible material fires. • Class B, Flammable liquid, gas or grease fires. • Class C, Energized-electrical equipment fires.  

• Fire extinguishers should be mounted within 75 feet of outside areas containing flammable liquids, and within 10 feet of any inside storage area for such materials

• Access to extinguishers should be free from obstructions or blockage

• Fire extinguishers must be serviced, maintained, and tagged at least once a year

ExtinguishersOrdinary Combustibles

Includes materials such as wood and paper

Flammable Liquids

Includes fuels, grease, other liquids

Electrical Fires

Contains non-conductive smothering agent

Fire Extinguisher Inspection

• Body of the extinguisher; rust, cracks, dents

• Check hose for cracks, dry-rot

• All fittings snug, no signs of leaks

• Lever and hinge assembly• Safety pin in place, safety

tie present• Inspection tag, present and

up to date• Pressure gauge, needle in

the green

How to use a Fire Extinguisher

P-A-S-SPull -- Pull the pin at the top of the extinguisher

that keeps the handle from being activatedAim -- Aim the nozzle at the base of the fireSqueeze -- Maintain a distance of eight to ten feet

away from the fire and squeeze the handle. Discharge will only occur if the handle is being squeezed.

Sweep -- Sweep the nozzle back and forth at the base of the fire until it appears to be out.

Basic First Aid

• The OSHA First Aid standard (29 CFR 1910.151) requires trained first-aid providers at all workplaces of any size if there is no “infirmary, clinic, or hospital in near proximity to the workplace which is used for the treatment of all injured employees.”

Handling an Emergency

The three C’s, Check, Call, Care help us remember what to do in an emergency situation.

Check – check the area for your own safety first, then the victim's

Call – for help, 911 or whom ever is in the immediate area that can provide assistance

Care - administer care to the victim, this may be first aid or at least stabilization