Dora James, CIH, CSP, MPH Valero Benicia Refinery

Industrial Hygienist

Recognition Cal-OSHA Title 8 3395. Heat Illness Prevention Understanding the Causes of Heat Illness Weather, Work, Personal Risk Factors

Controls Written Program Education for Supervisor and Employees Water availability Shade –Pop up Tents Work /Rest schedule JHA expectations One Page Field Document

Evaluation WBGT instrument Test specific work location

HEAT STRESS PREVENTIONRULES CHANGE IN CALIFORNIA

SITUATION Heat Stress Law changed in Californiaeffective May 2015 Major Changes • Water Availability • Shade present for all outdoor workers 80ºF • Acclimation period of 2 weeks • High Heat defined at 95 F • “effective monitoring” of workers for signs of heat stress• 10 minute - cool down rest periods include supervisory

oversight for heat stress symptoms• Emergency Response procedures include effective

communication (cell phones must work and have signal) for assistance

Actions• Supervisors and employees receive training on

recognizing and reducing heat illness • Supervisors implement acclimatization program for new

and returning employees - 14 days• All participants are aware of heat stress

countermeasures: hydration, physical fitness, diet, meals, and avoidance of over the counter medications, dietary supplements (creatine, ephedra, fat burners), alcohol, excessive caffeine, including energy drinks)

• Safety Professionals modify Heat Stress Programs to address changes

References

• Cal-OSHA Title 8 3395. Heat Illness Prevention

• Valero Benicia APM 6-4-34 Heat Stress Prevention

• APM 6-34 Table 1 Field Procedures and Controls Table

:

Objectives

• Site employees avoid a Heat Stress Injury

• Safety Coordinators include Heat Stress Program changes on the risk management matrix and JHA s

• Work plans include controls for Heat Stress

• Only medically cleared individuals work in hot environments

• Add Heat Stress and Awareness Training to training plans

Weather High humidity (WBGT, Heat Index)Ambient temperatureRadiant HeatAir movement

Work & WorkplaceHigh exertionHeavy loadsRepeated strenuous days

Personal Risk FactorsBeing well hydratedBeing physically fit Lack of AcclimatizationBody mass index (BMI) Age>40PregnancyMinor illnessMedication (e.g. antihistamine, blood pressure, decongestants)Alcohol past 24 hoursPrior heat injurySkin rash, sunburn, or poison ivyBlood donation (<3 days)Sleep deprived

ALSO: Highly motivated (push self & ignore symptoms)

Understanding the Causes of Heat Illness

Key Terms

Total Body Heat Stress = Total Heat Loadon an individual

Heat generated by the body

(due to metabolism and

activity)

+ Heat gained

from the environment

-Heat lost

in the environment

Air Temperature& Humidity

Solar radiation

Evaporation & Humidity

Convection(air currents)

Metabolic (internal)

Heat Production

Heavy Work Load

Conduction(contact with surfaces)

Temperature& Humidity

Solar radiation

Evaporation & Humidity

Convection(air currents)

Metabolic (internal)

Heat Production

Moderate Work Load

Conduction(contact with surfaces)

Presenter

Presentation Notes

The State of California reviewed heat stress cases and reported (80%) occurred during the three to four days when a new unacclimatized worker was introduced to a hot environment. The majority (50%) occur within the first 3-4 hours. Allow people to adapt to the heat. This includes new hires, those who have been on vacation or away from the work environment, or the first hot, humid weather of the season. People most susceptible to heat stress (see risk factors) should be medically cleared and supervised with a gradual introduction to the work environment (2-3 hours a day, for three days) for the initial 14 days. DRUGS THAT INTERFERE WITH TEMPERATURE REGULATION: Antihistamines (benadryl, atarax, ctm) Decongestants (sudafed) High Blood Pressure (diuretics, beta blockers) Psychiatric Drugs (tricyclic antidepressants, antipsychotics NOTE) there is currently NO scientific evidence that caffeine, energy drinks, “fat burners” or dietary supplements affect the body’s ability to regulate heat. Why Highly motivated personnel are at risk- the desire to meet or exceed standards may lead people to push themselves as early signs/symptoms of heat illness occur. Supervisors should be aware of people’s tendency to work hard and push themselves. In an effort to finish the job early and complete the tasks. Some individuals will skip breaks and unnecessarily put themselves at risk

□ CATEGORY II (MEDIUM) (Ambient 85-94° Nomex or 70 - 84°F in multilayered PPE) Complete all of Category I and this section□Determine a work/rest schedule.□Document the Work Load as

o Light o Moderate o Heavy

□ Monitor team for heat stress, hydration and mental status (name, location). Fill in the Table 3 Work/Rest Log APM 6-4-34.

□ Use a WBGT or the Heat Index to document decision logic.

For general outdoor work, □if no radiant equipment is nearby, use the WGBT temperature from the Services BLDG

□ CATEGORY III (HIGH) (Ambient 95–100°F Nomex or 85 - 94°F in multilayered PPE )

Complete all of Category I & II plus this section.

Determine if the work crew will work continuously for an hour wearing multi layered PPE.

□ If no, select the corresponding work/rest schedule using a Wet Bulb Globe Thermometer (WBGT). APM 6-4-34 Table 5.

□ If yes, schedule a REHAB Team for physiological monitoring. APM 6-4-34 Field Controls

□ WBGT at Location ______F Normal Work Clothes

o Continuous Work o 75/25 (WBGT 87°F Light

Work)o 50/50 (WBGT 89°F Light

Work) o 25/75 (WBGT 90°F Light

Work)(See Back Page)

Select one more control to Complete Category III Shield the hot surfaces from the workers □Temporary insulate the hot surfaces□Add reflective barriers for radiant heat

Provide additional personnel □For jobs with short (15 minutes) work/rest schedules include worker rotation and stage extra personnel

Cool the person during the task□Personal cooling devices (e.g., cool vests) vortex tubes □Spot cooling (fan or air-conditioning □Supplied air respiratory protection□Powered Air Purifying Respirators under Aluminized Suit (EADC)

Cool the Person on break □Access to air conditioning for a break area (Unit Shelter, swamp cooler, van, trailer, vehicle set up for REHAB) □Build a temporary dedicated area with mechanical ventilation (hooch), the primary function or the area is cooling and at least 75% of the area must be a seated rest zone

□ CATEGORY IV (EXTREME HEAT) (Ambient >100°F in Nomex; >95°F in multilayered PPE)

For CATEGORY IV environments, complete Categories I, II and III, AND obtain the Safety Manager’s signature OR schedule the work during the cooler part of the day.

Wet Bulb Globe Temperature establishes work/rest schedules

WBGT is a composite temperature used to estimate the effect of temperature, humidity, and radiant heat (usually sunlight) on humans

Tw = Natural Wet Bulb (evaporative cooling)Tg = Black Globe Thermometer (radiant heat) Td = Dry Bulb (ambient temperature )

------------- Work Load* ------------

Work/rest regimen

Light Moderate Heavy

Continuous work 30.0°C (86°F) 26.7°C (80°F) 25.0°C (77°F)

75% Work, 25% rest, each hour

30.6°C (87°F) 28.0°C (82°F) 25.9°C (78°F)

50% Work, 50% rest, each hour

31.4°C (89°F) 29.4°C (85°F) 27.9°C (82°F)

25% Work, 75% rest, each hour

32.2°C (90°F) 31.1°C (88°F) 30.0°C (86°F)

*Values are in °C and °F, WBGT.

Source: OSHA Technical Manual

TABLE 5PERMISSIBLE HEAT EXPOSURE THRESHOLD LIMIT VALUE ESTABLISHED WITH THE WBGT

Metabolic Rate Categories and the Representative Metabolic Rate with Example Activities

Add 5°F for workers in chemical protective clothing.

Add 10°F for workers in chemical protective clothing and performing heavy work.

Special Note: Workers in impermeable clothing, respirator protection, aluminized Suit, Bunker Gear, RainGear, Acid/Caustic Suits, Level A or B protection, disposable coveralls (Tyvek), welding, leathers, etc for greaterthan one hour continuously, require the support of a FIRE DEPT TEAM MEMBER REHAB TEAM to conductphysiological monitoring of pulse, temperature, or blood pressure (use Fire Dept Haz Mat Log or similar).

Model/Manufacturer Approx Price WBGT

Kestrel 4600 Pro Heat Stress Tracker

$590

Kestrel 4400 Heat Stress Tracker (WBGT,TWL)

$459

Extech HT200 Heat Stress WBGT Meter

$399

Heat Stress WBGT (Wet Bulb Globe Temperature) Meter HT30

$199

REED SD-2010 Heat Stress Meter Datalogger

$659

3M QUESTemp® QT32, QT34, QT36 Wet Bulb Globe Temperature Heat Stress Monitors

$2900 intrinsically

safe

Sigma Products WET BULB-GLOBE TEMPERATURE KIT

$285

*All devices need a tripod or tripod kit.

Alkylation Unit,R-1007 and D-1003 Deblinding, July 28, 2015

During de-blinding, Contractor wore 3M full-facerespirators with multigas cartridges.

Contract crew wore chemical protective clothingconsisting of a yellow slicker top and bottoms,hard hat, black neoprene gloves, mono-goggles,and steel toed boots.

The work load was considered moderate(sustained hand, arm trunk work, carrying lightloads).

Description D-1003 Services BldgRun Time (min) 5:24:40 5:36:00Dry Bulb Avg 84.4°F 92.2 °F

Globe Avg 88.2°F 118°F Heat Index Avg 77 °F 80.1°FHumidity Avg 34.5 % 15.8

WBGT Outdoors Avg 73.2 °F Add 10

89.3 °F

Work/Rest Moderate Work Load

75/25% work/rest regimen

50% Work, 50% rest, each hour

When compared to the Services Bldg temperature measurements, the Alkylation Unit D-1003 was significantly cooler.

Shade from D-1003, air movement under the drum, reduced radiant heat, and evaporative cooling created a work environment where those performing moderate work in chemical protective clothing and full face air purifying respirator adopted a 75/25% work/rest schedule.

Rolling Primer on Floating Roof Tank, TK‐1776, Tank Task Force

When the contractors moved out of the sun to roll primer in the tank shadow, the WBGT meter was also moved. The recorded globe/radiant heat changed 43°F from a 105°F to 65°F; and, ambient temperature changed from 89.7°F to 65.2°F. The measured WBGT index of 76.8°F supports a Continuous Work/rest schedule for moderate work activities, such as painting and carrying light loads.

Tank Task Force included engineering and administrative controls, shade, water, an adjusted 6 AM schedule and a WBGT to verify environmental conditions over the course of the work period. The work was expected to last five days.

Description E-703A1’ from SE

Corner

Between E703 A & B

Slurry Oil Valves & Piping

Breezeway under Pipe Rack &

Scaffold

Services Bldg(Background)@ 1550 PM

Dry Bulb Avg (Max)

107.7°F (102.5 °F)

109.6 °F (105.9°F)

120 °F (133.6°F)

99.3°F (98.7°F)

100.1°F

Globe Avg (Max)

131.4°F (125.6°F)

147.5°F (138°F)

175.8°F (196.5°F)

102°F(101.1°F)

119 °F

Humidity Avg (Max)

15.9%(20%)

10.1% (14%)

8.8% (14%)

13.6% (19.7%)

11%

WBGT Outdoors Avg 89°F 91.2°F 109.7°F 78.2°F 84.1°F

Work/Rest Regimen(Light vs Moderate)

50% /50% to 25% /75%

0%/100% 0%/100% Self pacedcontinuous

Self pacedcontinuous

The FCCU Unit workplace temperatures in thevicinity of slurry oil valves and E703 A&B wereprofiled to assist the Turnaround Planners withcompleting the high heat authorization.

FCCU Unit E-703 A& B Insulation Removal

The data collected adjacent to the FCCU slurry oil valves exceeded the published Wet Bulb Globe Temperature (WBGT) tables indicating strict heat prevention measures were needed.

A second option is follow the Eastman Kodak Company published work rest schedules based on temperature wherein light work is permitted for 5 minutes in temperatures up to 146°F and for 15 minutes up to 128°F

On Friday, August 14, 2015, Routine Maintenance established heat stress exposure controls for planned work at the Coker Deck 1.5 near R‐901

. The work task involved removal, fabrication, and the replacement of the hot solids line. The material of construction was stainless steel requiring half‐face respiratory protection and welders gloves.

The general and job site specific heat stress controls included adjusting the schedule to 6 AM start time, shielding radiant heat with Pyrogel insulation, spot cooling with mechanical air conditioning, and the use of a WBGT to adjust the work rest schedule based on environmental conditions.

Description Hot Solids LineScaffold Area

Insulated with Pyrogel2:30 PM

West of R-901

No Insulation2:11 PM

Services Bldg(Background)

@ 2:13 PM

Dry Bulb Avg (Max) 89.3°F (91.5 °F) 92.0 °F (94.2°F)

82.9°F

Globe Avg (Max) 94.6°F (96.1°F) 99.9°F (102.2°F) 103.8 °F

Humidity Avg (Max) 39.2 % (46%) 32.6% (37%) 30%

WBGT Outdoors Avg (Max) 72.3°F 81°F (83°F)

78.2°F

WBGT with 5 added (for PPE usage & moderate work)

77 And 82 86

Work/Rest Regimen(Moderate workload)

Self pacedcontinuous 50% /50% Self paced

continuous

Welding Stainless Steel, near R‐901, Coker

Pipestill, Fourth Deck, F-106 CO Line, July 28, 2015

Maintenance planned to torque 60 bolts tomitigate a leaking flange.

The time for task completion is 3 hours and thework requires air-line respiratory protection for aircontaminates SO2 and CO.

The work load is expected to be moderate.

The data supports a 25/75% work rest scheduleon the East Side of the CO line.

Maintenance planned to include heat stresscontrols, water, cooling fans, shift the start timeto 6AM, and a WBGT to verify environmentalconditions over the course of the work period.

As a reminder, work in extreme heat, >100°Frequires the signature of the Safety Manager.

Description Scaffold East CO Line Services BldgRun Time (min) 00:17:54 09:39:00Dry Bulb Avg 101.9 °F 90.3 °F

Globe Avg 113.5 °F 107.2 °F Heat Index Avg 95.5 °F 82.2°FHumidity Avg 21.5 % 46.0 %

WBGT Outdoors AvgMust add 5

81.1 °F 71.3 °F

Work/Rest Moderate Work Load

25% / 75% each hour

Continuous

Exertional Heat Illness (EHI)Refers to a spectrum of disorders (e.g., cramps, heat exhaustion, heat injury, heat

stroke) resulting from total body heat stress. Primarily heat casualties are forms of heat exhaustion while more severe cases are heat stroke (potentially fatal).

CDC Heat Stress Report 2012-2013During 2012‒2013, a total of 20 cases were cited for federal enforcement under paragraph 5(a)(1). Thirteen cases involved a worker death attributed to heat exposure, and seven involved two or more workers with symptoms of heat illness. Thirteen worksites wereoutdoors.

In eight cases, workers performed heavy work, and in 12 cases they performed moderate work per American Conference of Governmental Industrial Hygienists workload definitions (2).

Seven cases occurred in indoor facilities with a local heat source, such as laundry equipment or combustion engines. The cases occurred in various workplaces, including two in solid waste collection, two in mail delivery, nine in outdoor worksites (e.g., ship repair, landscaping, roofing, and oil servicing), two in laundries, and five in indoor worksites with machinery or other heat sources.

All heat illnesses and deaths occurred on days with a heat index in the range of 84.0°F–105.7°F (29.0°C–41.0°C), although those working in direct sunlight might have experienced a heat index that was up to 15.0°F (8.3°C) higher than reported (3).

Thirteen employers had not incorporated an approach to identifying heat illness risk (e.g., heat index), as described by the National Oceanic and Atmospheric Administration, into their heat illness prevention program (4).

None of the employer heat illness prevention programs were complete.

Twelve had no program at all, seven provided inadequate water management, and 13 failed to provide shaded rest areas.

Only one of the employers used work-rest cycles (i.e., scheduled periods of rest between periods of work based on temperature, humidity, and the intensity of the work activity), and none had an acclimatization program (Table).

Four of the 13 deaths occurred on the first day at work in a new job or after returning from time away from the job, three on the second day, and two on the third day; four deaths occurred among long-time employees. In the cases that involved heat illness but not a

death, the number of days on the job did not appear to contribute to any of the heat-related incidents.

TABLE. Summary of heat illness and fatality cases cited by the Occupational Safety and Health Administration (OSHA)* —United States, 2012–2013

Age(yrs) Fatality

Type of employme

nt

Temperature (heat index) at time of incident

Time employed

Overall employer program present

Employer provided

water and supported use

Employer provided

rest opportuni

ties

Employer provided cool or

shaded area

Work-rest

cycle

Acclimatization

program

Local uncontrolle

d heat source

(indoor)

Clothing

47 Yes Waste collection

91.0°F, 32.8°C(93.8°F, 34.3°C)

1 day No NoOnly on

scheduled breaks

No No No None

Wearing two

flannel shirts

Unknown (multiple workers)

No

HVAC systems

manufacturing

98.6°F, 37.0°C

(105.5°F, 40.8°C)

Unknown No No Limited breaks No No No

Plant machinery, inoperable

A/C

Unknown

47 Yes Asphalt paving

97.0°F, 36.1°C(99.9°F, 37.7°C)

3 days No YesScheduled and water

breaksNo No No

Asphalt paver

machine, hot asphalt

Unknown

39 Yes

Synthetic turf

installation

91.9°F, 33.3°C

(92.5°F, 33.6°C)

2 days Yes Yes Scheduled breaks No No No

Synthetic turf

materialUnknown

Unknown No Commercial laundry

93.9°F, 34.4°C

(102.1°F, 38.4°C)

Unknown No Yes Scheduled breaks Yes Yes† No

Irons, washers,

dryers, no A/C or

fans

Unknown

• Temperature (heat index) at time of incident• Employer written program • Employer provided water and supported use• Employer provided rest opportunities• Employer provided cool or shaded area• Work-rest cycle• Acclimatization program• Local uncontrolled heat source (indoor)• Clothing contribution

Be more than Compliant. Be Confident.

Implement your Heat Stress Guidelines

Recognition Cal-OSHA Title 8 3395. Heat Illness Prevention Understanding the Causes of Heat Illness Weather, Work, Personal Risk Factors

Controls Written Program One Page Field Document Education for Supervisor and Employees JHA expectations Hydration and water availability Shade Work /Rest schedule

Evaluation WBGT instrument Test specific work location

QUESTIONS