Occupational Safety and Health Simplified for the Chemical Industry

Occupational Safety and Health Simplified for the Chemical Industry
Frank R. Spellman, Revonna M. Bieber
Contents
iii
Preface v
Prologue vii
1 Introduction 1
2 Safety Is a Four-Letter Word 13
3 The Chemical Industry 21
4 Learning from the Past 27
5 Chemical Safety and Hazard Communication 37
6 Process Safety Management and Risk Management Planning 65
7 Chemical Hygiene Plan 91
8 Safety Showers/Eyewash Stations 121
9 Chemical Safety Program 131
Appendix: Chemical Guide A–X 167
Index 191
About the Authors 195
Index
191
accident prevention, 15
accident reporting, 118
acid rain, 3
acid safety, 13–139
acid spill kit, 107
acute toxins, 143
aerosol, 5
air cleaner, 147
airflow check, 151
albuminate, 137
alternative release scenario, 77
amyl nitrite, 110
anhydride, 137
aqueous, 137
audits, 63–64
base safety, 138–39
behavior-based safety, 13–19
Bhopal, 2
Bhopal-like incident, 3
boiling point, 67
capturing hood, 147
carboy, 137
carcinogen, 96, 144
catastrophic release, 67
centrifuge safety, 161
checklist approach, 74
chemical, 55, 96
chemical accidents, 28–34
chemical burns, 108
Chemical Diversion and Trafficking Act
(CDTA), 25
chemical exposure, 154
chemical handling, 105
Chemical Hygiene Plan, 4, 64, 91–119
chemical industry, 1, 21–25; components of,
21–22
chemical inventory, 44, 58
chemical occupations, 23
chemical safety, 2
chemical-safety equations, 19
chemical safety program, 131–64
chlorine, 16
chronic toxins, 144
Clean Air Act (CAA), 24
cleaning agents, 145
Clean Water Act (CWA), 24
coefficient of expansion, 137
combustible liquid, 5, 55, 97
common flammables, 141
compliance audits, 72
Comprehensive Environmental Response
Compensation and Liabilities Act of 1980
(CERCLA), 24
compressed gas, 5, 56, 97
compressed gas cylinders, 159
compressed gas safety, 159
Consumer Product Safety Act, 25
container labeling, 111
contractors, 53, 62, 71
corrosives, 5, 97cryogenic gases, 158
cyanide poisoning, 109
deluge showers, 126–27
dysfunctional fear, 18
dysfunctional leadership, 35
electrical safety, 157–58
Emergency Planning and Community Rightto-Know Act, 24
emergency planning and response, 72
emergency response, 151–62
employee involvement, 70
enclosure hood, 147
environmental receptor, 79
ester, 137
estimating distance, 77
exhaust hoods, 149
exhaust stack, 147
explosive, 56
explosive limits, 140
eyewash fountains, 124
eyewash requirements, 126
eyewash squeeze bottles, 128
eyewash stations, 121–29
face velocities, 149, 151
Failure Mode and Effect Analysis (FMEA),
75
fall protection, 162
Fault Tree Analysis, 75
fear, 13–20
Federal Alcohol Administration Act, 7
Federal Food Drug and Cosmetics Act
(FDCA), 7, 24
Federal Hazardous Substance Act, 7
Federal Insecticide, Fungicide, and
Rodenticide Act (FIFRA), 24
fire extinguishers, 156–57
fire types (classes), 156–57
first aid for electrical shock, 158
flammable, 97
flammable aerosol, 56
flammable classes, 141
Flammable Fabrics Act, 25
flammable gas, 56
flammable liquid, 56
flammable solid, 56
flammables, 139
flashpoint, 56, 98
fume hood management, 115
fume hoods, 148–49
functional fear, 18
general exhaust ventilation, 146
glass safety, 158
gloves, 103–4
halide, 137
halogen, 137
hazard assessment, 77
hazard communication, 37–63
hazard warning, 56, 60
hazardous chemical, 56
Hazardous Materials Identification System,
40
hazardous materials spills, 153–54
Hazardous Materials Transportation Act
25
hazardous waste, 112–14
HAZOP, 74–75
health hazard, 56
heat control ventilation, 148
Heinrich, H. W., 14
hierarchy of controls, 16–17
highly hazardous chemical, 67
hot work, 67, 71
hydrogen peroxide, 45–52
ignitable, 5
incident investigation, 72
industrial chemical, 22
irritant, 98, 144
keystone industry, 21
label, 98
litmus paper, 137
local exhaust ventilation, 146
lower explosive limit (LEL), 140
management of change, 71
material safety data sheets (MSDS), 43–52,
59–60, 134
mechanical integrity, 71
medical emergency, 162
192 INDEXmedical surveillance, 117
mercury spill, 108, 153
methyl isocyanate (mic), 2
microbiological hazards, 16
mixture, 57, 99
necklace label, 160
NFPA 704 B label, 40–41, 47, 136
Occupational Safety and Health Act (OSH
Act), 24
off-site, 85
operating procedures, 71
organic peroxide, 5, 57
OSHA, 8–11; standards of, 9–10
outage, 137
outdoor eyewashes, 129
oven safety, 158
oxidizer, 5, 57, 99
performance standard, 92
permissible exposure limits (PELs), 93, 99
personal hygiene, 135
pH scale, 137–38
pharmaceuticals, 22
physical hazard, 5, 57
pipetting safety, 162
Poison Packaging Prevention Act, 25
Pollution Prevention Act, 25
pre-startup, 71
preventing fires, 155
process, 79
process hazard analysis (PHA), 71
process safety information, 70
Process Safety Management (PSM), 2, 65–67
protective equipment, 101
public receptor, 79
pyrophoric, 6, 57, 99
reactives, 5, 145
receiving hood, 147
regulated substance, 79
replacement in kind, 67
reproductive toxins, 144
Resource Conservation and Recovery Act
(RCRA), 24
Risk Management Planning (RMP), 28,
65–67; program levels of, 80–82
Safe Drinking Water Act, 25
safe work practices for chemical workers,
163–64
safety officer, 94
safety showers, 121–29
sample hazard communication program,
54–64
saponify, 138
sensitizers, 144
signal words, 6, 40
significant accidental release, 85
siphoning safety, 133
smoke tube, 151
sodium hypochlorite, 16
soil degradation, 3
solvent health hazards, 143
solvents, 142;
standards for, 142
standard operating procedures, 69
stationary container, 57
stationary source, 79, 85
sulfuric acid, 139
supply ventilation, 148
survival function, 17
testing hoods, 150
threshold quantity, 79
time weighted average (TWA), 8
Title 29 CFR, 10
toxic, 5
toxic chemicals, 143–44
Toxic Substances Control Act (TSCA), 7, 24
trade secret, 67, 72
training, 61–62, 71, 115
unstable, 6
unstable chemical, 57
upper explosive limit (UEL), 140
vacuum pumps, 158
ventilation, 146–51
vessel, 79
warning labels, 39–42
water-reactive, 6, 58, 99
what-if approach, 74
what-if/checklist, 74
worst-case scenario, 77

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