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Hazard and Risk Assessment Hazard and Risk Assessment
PDC on Hazard and Risk AssessmentPDC on Hazard and Risk Assessment
Occucon 2014, Goa
February 11, 2014
Maharshi Mehta, CSP, CIHInternational Safety Systems, Inc., Washingtonville New York, USAwww.issehs.com
AgendaAgenda
Introduction to Industrial HygieneIntroduction to Industrial Hygiene HazardsHazards
– Chemical Physical and Biologcal AgentsChemical Physical and Biologcal Agents Hazards and RiskHazards and Risk Exposure LimitsExposure Limits Risk Assessment ToolsRisk Assessment Tools Case Studies Case Studies Demonstration of Risk Assessment tools Demonstration of Risk Assessment tools
©International Safety Systems, Inc. ©International Safety Systems, Inc. www.issehs.comwww.issehs.com
Industrial HygieneIndustrial Hygiene
Hazard Anticipation-Hazards likely to be present?Hazard Anticipation-Hazards likely to be present?
Hazard Recognition-What are health hazards?Hazard Recognition-What are health hazards?
Risk Evaluation-Exposed to health hazard? How much? Risk Evaluation-Exposed to health hazard? How much?
Risk Control-How can exposure be reduced?Risk Control-How can exposure be reduced?
And potential for occupational illnesses, material loss are And potential for occupational illnesses, material loss are reduced and the company liability minimizedreduced and the company liability minimized
So that.. Health risk is minimizedSo that.. Health risk is minimized
The NeedThe Need Prevent occupational illness and injury by Prevent occupational illness and injury by
reducing/eliminating health riskreducing/eliminating health risk Significant cost savings by reducing/recovering Significant cost savings by reducing/recovering
particulate/vapor emissionsparticulate/vapor emissions Regulatory requirementsRegulatory requirements Productivity increaseProductivity increase
•In the Europe, 150 million workdays are lost each year due to work In the Europe, 150 million workdays are lost each year due to work accidents and illnesses and the insurance costs 20 billion Eurosaccidents and illnesses and the insurance costs 20 billion Euros•Annual cost of occupational illnesses and injuries in Latin America is Annual cost of occupational illnesses and injuries in Latin America is about $75 billionabout $75 billion
Exposure LimitsExposure Limits Airborne concentration of a substance Repeated exposure to the substance below exposure limit
day after day is unlikely to produce adverse health effects in healthy workers
High Health Hazard Chemicals have low exposure limits. Examples of exposure limits at Huntsman
– Hydrochloric acid 5 ppm ceiling limit– Ammonia 25 ppm long term limit for 8 hours exposure
Exposure limits are Exposure limits are notnota fine line between safe and a fine line between safe and dangerous concentrations dangerous concentrations
Organizations Establishing Organizations Establishing Occupational Exposure Limits Occupational Exposure Limits (OELs)(OELs)
American Conference of Governmental Industrial American Conference of Governmental Industrial Hygienists (ACGIH), USA Hygienists (ACGIH), USA
Local Regulatory AgenciesLocal Regulatory Agencies– Occupational Safety and Health Administration (OSHA), USAOccupational Safety and Health Administration (OSHA), USA
– Health and Safety Executive (HSE), UKHealth and Safety Executive (HSE), UK
– Technical Rules for Hazardous Substances (TRGS), GermanyTechnical Rules for Hazardous Substances (TRGS), Germany
GE Established OELsGE Established OELs– More stringentMore stringent
Units of Exposure LimitsUnits of Exposure Limits
Vapor/gaseous airborne substances:Vapor/gaseous airborne substances: ppm (parts per million)- the parts of airborne ppm (parts per million)- the parts of airborne
substance per million parts of airsubstance per million parts of air ppb (parts per billion)- the parts of airborne ppb (parts per billion)- the parts of airborne
substance per billion parts of airsubstance per billion parts of air
Expressed as concentration of the airborne substance in a volume of air Expressed as concentration of the airborne substance in a volume of air
Particulate airborne substances:Particulate airborne substances: mg/mmg/m33 - - milligrams of airborne milligrams of airborne substance per cubic meter of airsubstance per cubic meter of air µg/µg/mm33 - - micrograms of airborne micrograms of airborne substance per cubic meter of airsubstance per cubic meter of air
Airborne fibers:Airborne fibers:Fibers/cc -fibers per cubic Fibers/cc -fibers per cubic centimeter of aircentimeter of air
1 m
1 m
1 m
. 1 mg
Concentration of airborne substance is 1
mg/m3
What are Hazards and RisksWhat are Hazards and Risks Hazard – Chemical, Physical and or Biological agent that
can cause harm Risk - The likelihood that the potential for harm will be
caused by hazards Hazardous substances are present most of the time Risk is dependant on (a) human exposure to hazards and
(b) degree of exposures Degree of exposure is dependant on controls provided
and work practices followed
Industrial Hygiene Risk Assessment (IHRA) is process of Industrial Hygiene Risk Assessment (IHRA) is process of determining degree of health RISK based on degree of determining degree of health RISK based on degree of HAZARDS and extent of EXPOSUREHAZARDS and extent of EXPOSURE
The NeedThe Need Assist in determining: Assist in determining:
– the need for exposure controlsthe need for exposure controls– respiratory protection and types of respiratorsrespiratory protection and types of respirators– if an illness is work related or notif an illness is work related or not
Assist in protecting company in occupational illness litigationsAssist in protecting company in occupational illness litigations Targeted medical surveillanceTargeted medical surveillance
– Medical surveillance focused on potentially exposed Medical surveillance focused on potentially exposed individualsindividuals
Methodology - PlanningMethodology - Planning
Obtain and review process information, chemical Obtain and review process information, chemical lists before handlists before hand
Obtain and review past mentoring data and Obtain and review past mentoring data and historical assessmenthistorical assessment
Review floor plan and mark areas CRA to ensure Review floor plan and mark areas CRA to ensure all areas are coveredall areas are covered
Review applicable regulation and standardsReview applicable regulation and standards Obtain list of chemicals and ingredientsObtain list of chemicals and ingredients
Where and When Should Chemical Where and When Should Chemical Risk Assesment be DoneRisk Assesment be Done Where: Where:
– Include all operations and activitiesInclude all operations and activities– Include all non-routine operations and activities such Include all non-routine operations and activities such
as, maintenanceas, maintenance– Include activities with no apparent health risk alsoInclude activities with no apparent health risk also
E.g., Warehouse; potential risk from noise and E.g., Warehouse; potential risk from noise and carbon monoxide (CO) from forklift may be presentcarbon monoxide (CO) from forklift may be present
WhenWhen– Before any new process beginsBefore any new process begins– When change in process occursWhen change in process occurs
Required for Employees, Contract Employees, Temporary Required for Employees, Contract Employees, Temporary WorkersWorkers
Chemical Risk AssessmentChemical Risk Assessment Degree of hazards
– Hydrochloric acid and ammonia Frequency and duration of handling/exposure
– How long tanker unloading is done The risk of the material becoming airborne
– % of HCl and does it become airborne Historical air monitoring results (if available) Existing engineering controls and work practices followed
– How do we collect QC sample Effectiveness of exposure control is determined or not Chemical properties: volatility, particle size, dryness
– Fly ash , coal dust Ingestion Skin contact
Site VisitSite Visit Determine frequency/duration of operation/personal Determine frequency/duration of operation/personal
exposuresexposures Determine approximate quantities of materials usedDetermine approximate quantities of materials used Observe controls - make subjective assessment of Observe controls - make subjective assessment of
effectivenesseffectiveness Interview workers and/or supervisors at each stage of Interview workers and/or supervisors at each stage of
processprocess Gather data on raw materials, finished products, by-Gather data on raw materials, finished products, by-
productsproducts Collect relevant MSDSsCollect relevant MSDSs Note specific PPE usedNote specific PPE used Start to complete Risk RankingStart to complete Risk Ranking
©International Safety Systems, Inc. ©International Safety Systems, Inc. www.issehs.comwww.issehs.com
RankFrequency Duration
Health HazardAirborne Potential
Engineering Control
Skin Exposure
Daily Weekly monthly Yearly
Chemicals API Skin HazardExposure Potential
1 Minimal (under 30 minutes)
Any / Minimal (under 5 hours)
Any / Minimal (under 20
hours)
Any / Minimal
(under 250 hours)
OEL in range 3.1 to 10
mg/m3 or > 1000 ppm
OHC #1, OEL >1000 µg/m3 Low
Total enclosure validated by IH
monitoring
No skin hazard, temporary effects
2 About 30 min to < 2
hour5 to 15 hours
per week20 to 60 hours
per month
250 to 500 hours per
year
OEL in range 0.51 to 3
mg/m3 or 101 to 1000 ppm
OHC# 2, OEL 100 µg/m3 - 1000
µg/m3
MediumTotal enclosure NOT validated
3 About ½ Shift (2 to 4 hours)
15 to 25 hours per week
60 to 80 hours per month
Use More Frequent
Basis
OEL in range 0.01 to 0.5
mg/m3 or 10 to 100 ppm
OHC# 2, OEL 100 µg/m3 - 1000
µg/m3
High
4 About ¾ Shift (4 to 7 hours)
25 to 30 hours per week
Use More Frequent
Basis
Use More Frequent
Basis
OEL < 0.01 mg/m3 or < 10
ppm
OH Cat# 3, OEL 10 µg/m3 - 100
µg/m3
Moderate (LEV)
validated
Probable skin irritants, materials
may cause dermatitis.
Short term skin
exposure
5(over 7 hours)
Use More Frequent Basis
Use More Frequent
Basis
Use More Frequent
Basis
OH Cat# 4, OEL
1 µg/m3 - 10 µg/m3
6
Cat# 4, OEL 0.01 µg/m3 - 1 µg/m3
Moderate not
Validated
7
OH Cat# 4, OEL
< 0.01 µg/m3
Will cause skin irritation, sensitizers,
corrosives (acids, caustics, nickel).
Repeated-long Skin exposure
8
Non-fixed controls
movable LEV
9
10 No controlsMaterials toxic to
skin (ACGIH) Skin
Skin exposure certain
©International Safety Systems, Inc. ©International Safety Systems, Inc. www.issehs.comwww.issehs.com
Final Risk Ranking Criteria
Description
Final Risk
Ranking
<50
Acceptable – process is well controlled and personal exposures are obviously unlikely to become significant – no further action required other than periodic review
1
50-200Potentially acceptable but it may be possible to further reduce exposures by adopting simple recommendations
2
200-400
Further evaluation needed – the qualitative assessment has not provided enough information to be confident that personal exposures are acceptable; air monitoring may be required.
3
> 400 Very High Risk -Implement exposure controls immediately 4
Case Study-HCl unloadingCase Study-HCl unloading
37% HCl, how hazardous the chemical is?37% HCl, how hazardous the chemical is? Ceiling Limit of 2 ppmCeiling Limit of 2 ppm Unloading is done from tankerUnloading is done from tanker Closed pipingClosed piping Unloading is done for 2 hours/weekUnloading is done for 2 hours/week Is it harmful through skin?Is it harmful through skin? Skin Contact likely?Skin Contact likely? What is final riskWhat is final risk
©International Safety Systems, Inc. ©International Safety Systems, Inc. www.issehs.comwww.issehs.com
RankingRanking
1.1. Frequency Duration Ranking?Frequency Duration Ranking?
2.2. Hazard Ranking?Hazard Ranking?
3.3. Is it becoming easily airborne? Ranking?Is it becoming easily airborne? Ranking?
4.4. Are exposure controls provided? Effective? Are exposure controls provided? Effective? Ranking?Ranking?
Inhalation ranking multiplication of 1x2x3x4 Inhalation ranking multiplication of 1x2x3x4 rankingranking
Now what is inhalation ranking?Now what is inhalation ranking?
©International Safety Systems, Inc. ©International Safety Systems, Inc. www.issehs.comwww.issehs.com
Skin Ranking Skin Ranking
1.1. Is HCl very harmful to skin? What is ranking?Is HCl very harmful to skin? What is ranking?
2.2. Is skin contact likely? What is ranking?Is skin contact likely? What is ranking?
Skin Exposure ranking is 1x2Skin Exposure ranking is 1x2
What is skin exposure risk?What is skin exposure risk?
Total Risk is Inhalation Ranking + Skin RankingTotal Risk is Inhalation Ranking + Skin Ranking
What is Total Ranking?What is Total Ranking?
Is risk acceptable? What needs to be doneIs risk acceptable? What needs to be done
©International Safety Systems, Inc. ©International Safety Systems, Inc. www.issehs.comwww.issehs.com
Observations and Observations and RecommendationsRecommendations
Very important as observation based degree of risk is Very important as observation based degree of risk is more important than number based risk more important than number based risk
Provides bases for ranking used Provides bases for ranking used Obtain and enter as much of the pertinent information as Obtain and enter as much of the pertinent information as
possible based on observations and interviewspossible based on observations and interviews While making recommendations, considerWhile making recommendations, consider
– ““Quick Fix”Quick Fix”– FeasibilityFeasibility– Cost effectivenessCost effectiveness
Mention PPEs used, if anyMention PPEs used, if any
Quantitative Exposure AssessmentQuantitative Exposure Assessment
Chemical exposure monitoringChemical exposure monitoring– Direct reading instrumentsDirect reading instruments– Detector tubes (Colorimetric tubes)Detector tubes (Colorimetric tubes)– Passive monitoring with Diffusion badges/tubesPassive monitoring with Diffusion badges/tubes– Active monitoring with sampling pumpsActive monitoring with sampling pumps
Noise monitoringNoise monitoring– Area noise monitoringArea noise monitoring
– Personal noise exposure monitoring (Dosimetry)Personal noise exposure monitoring (Dosimetry) Heat stress monitoringHeat stress monitoring Ionizing radiation monitoringIonizing radiation monitoring Vibration monitoringVibration monitoring Bio-aerosol monitoringBio-aerosol monitoring
Active Air Active Air MonitoringMonitoring
Sampling pump
Sampling media
Sampling media
Active Air MonitoringActive Air Monitoring Process: Process:
– Air is drawn through a sampling media, kept in the breathing zone Air is drawn through a sampling media, kept in the breathing zone of the person potentially exposed, with a battery operated of the person potentially exposed, with a battery operated sampling pumpsampling pump
– The sampling media is analyzed and weight of contaminant The sampling media is analyzed and weight of contaminant determineddetermined
– The weight is divided by the volume of air drawn through the The weight is divided by the volume of air drawn through the media to determine contaminant concentrationmedia to determine contaminant concentration
Substance-specific accurate identification of exposureSubstance-specific accurate identification of exposure Corporate and regulatory requirementsCorporate and regulatory requirements Acceptable in litigationAcceptable in litigation Determines exposure during actual work. Not an Determines exposure during actual work. Not an
instantaneous concentration determination as in direct instantaneous concentration determination as in direct reading instrumentreading instrument
Quality Assurance in Exposure MonitoringQuality Assurance in Exposure Monitoring
Health of working people depends on exposure monitoring resultsHealth of working people depends on exposure monitoring results Ensure sampling duration is closed to the exposure duration. Ensure sampling duration is closed to the exposure duration.
– Do not miss beginning and ending of shifts as high exposure Do not miss beginning and ending of shifts as high exposure may occur during this time (e.g., cleaning of work area) may occur during this time (e.g., cleaning of work area)
– Exposure monitoring may have to begin at 6 am if shift starts at Exposure monitoring may have to begin at 6 am if shift starts at 6 am. 6 am.
Ensure calibration of sampling device before and after samplingEnsure calibration of sampling device before and after sampling Ensure sampling device is calibrated annuallyEnsure sampling device is calibrated annually Ensure sampling time is exact. Ensure sampling time does not end Ensure sampling time is exact. Ensure sampling time does not end
with 0 and 5 (e.g., 8:05 am, 8:10 am)with 0 and 5 (e.g., 8:05 am, 8:10 am)
Demonstration of Risk Demonstration of Risk Assessment Tool and DiscussionsAssessment Tool and Discussions
Control Of Substances hazardous to Health Control Of Substances hazardous to Health (COSHH) Risk Assessment Tool(COSHH) Risk Assessment Tool
Industrial Hygiene Risk Assessment Tool at one Industrial Hygiene Risk Assessment Tool at one of the largest corporationsof the largest corporations– ProcessProcess
– Computerized modelComputerized model
– Data Synthesis and analysis for 2000 + sites globallyData Synthesis and analysis for 2000 + sites globally
©International Safety Systems, Inc. ©International Safety Systems, Inc. www.issehs.comwww.issehs.com
COSHH Assessment Tool-Part 1COSHH Assessment Tool-Part 1
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COSHH Assessment Part 2COSHH Assessment Part 2
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COSHH Assessment Part 3COSHH Assessment Part 3
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COSHH Assessment Part 4COSHH Assessment Part 4
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Enhanced IH ModuleEnhanced IH ModuleAssessment w/Risk Assessment integrated into IH module
Enhanced IH Module (Cont.)Enhanced IH Module (Cont.)Streamlined Add New Assessment form
Risk Assessment Details section
Enhanced IH Module (Cont.)Enhanced IH Module (Cont.)Risk Assessment Details Pending for an Existing Assessment Record
Risk Assessment Details Completed
Enhanced IH Module (Cont.)Enhanced IH Module (Cont.)Streamlined Risk Assessment Details Form with Guidance Mouseovers
Enhanced IH Module (Cont)Enhanced IH Module (Cont)
Risk Assessment Workflow Option to Submit to Reviewer
Enhanced IH Module (Cont.)Enhanced IH Module (Cont.)Risk Assessment Review Option – Special Right Required
HSE (UK) COSHH EssentialsHSE (UK) COSHH Essentials Control banding tool for small to medium size Control banding tool for small to medium size
enterprises to do risk assessments for chemicals & enterprises to do risk assessments for chemicals & mixtures of chemicalsmixtures of chemicals
Required informationRequired information– Type of task – shoveling, drillingType of task – shoveling, drilling– Hazard classification (using risk & safety phrases Hazard classification (using risk & safety phrases
from MSDS )from MSDS )– Volatility or dustiness (from guidance material)Volatility or dustiness (from guidance material)– Amount used- kg,mg,litres,millilitersAmount used- kg,mg,litres,milliliters
HSE (UK) COSHH Essentials HSE (UK) COSHH Essentials (cont)(cont)
System identifiesSystem identifies
– Control band (control approach)Control band (control approach)
– Produces advice on controlling risk from the Produces advice on controlling risk from the chemical being used in the taskchemical being used in the task
– Provides written guidance & documentationProvides written guidance & documentation
ILO Chemical Control Tool kitILO Chemical Control Tool kit
Very similar to COSHH EssentialsVery similar to COSHH Essentials
Does not apply to process dusts or fumes due to the Does not apply to process dusts or fumes due to the fact that these are not classified by the supplier of fact that these are not classified by the supplier of individual chemicalsindividual chemicals
Has general application to many situations in Has general application to many situations in developing countries but susceptible groups (child developing countries but susceptible groups (child workers & pregnant women) need to be consideredworkers & pregnant women) need to be considered
Stages of the ILO Chemical Stages of the ILO Chemical Control ToolkitControl Toolkit
Stage 1 – Hazard ClassificationStage 1 – Hazard Classification
Stage 1 – Hazard Classification Stage 1 – Hazard Classification (cont)(cont)
Stage 2 – How Much is UsedStage 2 – How Much is Used
Stage 3 - DustinessStage 3 - Dustiness
Stage 3 – VolatilityStage 3 – Volatility
Source: ILO toolkit
Stage 4 – Control ApproachStage 4 – Control Approach
Source: ILO toolkit
Stage 5 – Task Specific Control Guidance Stage 5 – Task Specific Control Guidance SheetSheet
Source: ILO toolkit
Stage 5 – Task Specific Control Guidance Stage 5 – Task Specific Control Guidance SheetSheet
Source: ILO toolkit
Stage 5 – Task Specific Control Guidance Stage 5 – Task Specific Control Guidance SheetSheet
Source: ILO toolkit
Lessons LearnedLessons Learned
Understanding Hazard is prerequisite to risk Understanding Hazard is prerequisite to risk assessmentassessment
Risk Assessment is essential to determine degree Risk Assessment is essential to determine degree exposure controlsexposure controls
Comprehensive Risk Assessment reduces over all Comprehensive Risk Assessment reduces over all cost of exposure monitoring and provides opportunity cost of exposure monitoring and provides opportunity to implement exposure controls before monitoringto implement exposure controls before monitoring
Above all: Adds few days, months or years in to life Above all: Adds few days, months or years in to life of working people. of working people.
©International Safety Systems, Inc. ©International Safety Systems, Inc. www.issehs.comwww.issehs.com