an effective industrial hygiene program · 1 an effective industrial hygiene program andrew...
TRANSCRIPT
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An Effective Industrial Hygiene ProgramAndrew Boester, CIH
Justin Hoover, MS, CSP
Tuesday March 13, 2018
WHAT IS INDUSTRIAL HYGIENE
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WHAT IS INDUSTRIAL HYGIENE
The Science and Art devoted to the ANTICIPATION, RECOGNITION, EVALUATION and CONTROL of occupational hazards
WHEN SHOULD WE DO INDUSTRIAL HYGIENE?
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EVALUATION
• Sampling Questions• Who
• What
• When
• Where
• How
• Third Party or Local?• Advantages / Disadvantages
CONTROL
• ELIMINATE
• SUBSTITUTION
• ENGINEERING
• ADMINISTRATIVE
• PPE
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ONLY PART OF THE STORY
• Sampling at paint line once per year• Different paint types have different agents at different concentrations
• Custom work on stainless steel• Conducted infrequently (project‐based)• Results in wildly varied exposure potentials
• Ladle Drying process• The process involves heating a newly‐rebricked ladle to use temperature. Binder used can release formaldehyde gas
• “Should’ve been here yesterday”
INDUSTRIAL HYGIENE PROGRAM
• Can include• A comprehensive written program
• Management commitment / policy statement
• Sampling strategy
• Data Management System
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INTEGRATING IH INTO YOUR FACILITY’S CURRENT PROGRAMS• PPE
• HAZARD COMMUNICATION
• CONFINED SPACE
• HEARING CONSERVATION
• RESPIRATORY PROTECTION
• THERMAL STRESS MANAGEMENT
• EXPOSURE CONTROL PROGRAM(S)
DATA MANAGEMENT SOFTWARE
• IH RASP• More on this in a minute
• PURCHASED SOFTWARE
SOLUTIONS
• CUSTOM DATABASES
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RISK ASSESSMENT AND SAMPLING PLAN• RISK ASSESSMENT
• A Qualitative judgement about the agents and hazards associated with work tasks throughout the facility
• SAMPLING PLAN• A prescribed frequency of sampling at each location for each agent, based on the results of the Risk Assessment, and the bank of current sampling data.
THE RISK ASSESSMENT
• RISK
• HAZARD SEVERITY• How “bad” the agent is
• HAZARD PROBABILITY• How likely to be exposed
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THE RISK ASSESSMENT
RISK SCORE Hazard Severity
Not Particularly Toxic (Minor irritation, etc.)
Moderately Toxic (Irritants, Chronic Effects Possible)
Quite ToxicPossible
Carcinogens,Chronic Effects
Very Toxic, Carcinogenic, Chronic Effects
Hazard Probability 1 2 3 4
Exposure is not likely
1 1 2 3 4
Minimal Likelihood(startup / shutdown or brief tasks)
2 2 4 6 8
Moderate Likelihood (intermittent exposures during workshift)
3 3 6 9 12
High Likelihood (significant exposure likely over entire shift)
4 4 8 12 16
THE RISK ASSESSMENT MATRIXHEG_ID Assessment
Date
Department Job/Task P/NP # Empl Description Agent Source
Haz Sev
Haz Prob
Raw Risk Frequency
(Disregarding
Monitoring)
SB‐001 5/28/2015 Melt Deck First Helper P 8 Respirable Particulates Scrap Metal, Fluxes, General
Dust2 4 8 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Quartz Insulating Materials 4 4 16 Quarterly
SB‐001 5/28/2015 Melt Deck First Helper P 8 Lead Scrap Metal 4 3 12 Semi‐Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Iron oxide Scrap Metal 3 3 9 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Manganese Scrap Metal 4 3 12 Semi‐Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Zinc oxide Scrap Metal 3 3 9 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Aluminum Scrap Metal 3 3 9 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Antimony Scrap Metal 3 3 9 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Arsenic Scrap Metal 4 2 8 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Barium Scrap Metal 3 2 6 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Beryl lium Scrap Metal 4 2 8 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Cadmium Scrap Metal 4 2 8 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Chromium, Trivalent Scrap Metal 3 2 6 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Cobalt Scrap Metal 3 2 6 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Copper Scrap Metal 4 2 8 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Nickel Scrap Metal 2 2 4 Biennial
SB‐001 5/28/2015 Melt Deck First Helper P 8 Selenium Scrap Metal 2 2 4 Biennial
SB‐001 5/28/2015 Melt Deck First Helper P 8 Thall ium Scrap Metal 3 2 6 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Vanadium pentoxide Scrap Metal 3 2 6 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Molybdenum Scrap Metal 2 2 4 Biennial
SB‐001 5/28/2015 Melt Deck First Helper P 8 Heat Stress Ambient and Furnace 2 2 4 Biennial
SB‐001 5/28/2015 Melt Deck First Helper P 8 Carbon monoxide Combustion 2 4 8 Annual
SB‐001 5/28/2015 Melt Deck First Helper P 8 Cold Stress Ambient 2 2 4 Biennial
SB‐001 5/28/2015 Melt Deck First Helper P 8 Occupational Noise Furnace Charging 3 4 12 Semi‐Annual
Melt Deck employees alternate
their time between the Pulpit
(Control Room), and the furace
area. The First Helper spends
nearly 100% of the time inside
the control room, which is
environment and temperature
control led. There is a small
chance that the First Helper
wil l be needed on the Melt
Deck to help tap the furance,
collect samples, fil l tap holes
or clean the deck.
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THE RISK ASSESSMENTSAMPLING INFO.
DATA SIZE
Minimal Sample Size
(n < 6)
Small Sample Size
(n 6‐15)
Moderate Sample Size (n 15‐30)
Well Characterized Data Set (n > 30)
Average % of Limit 0.5 1 1.5 2
100% or Greater 0.5 0.25 0.5 0.75 1
75‐100% 1 0.5 1 1.5 2
50‐75% 1.5 0.75 1.5 2.25 3
Less than 50% 2 1 2 3 4
CALCULATING THE RISK SCORE
• SAMPLE MATRIX AND FINAL SCORE
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SAMPLING FREQUENCY
• FINAL RISK SCORE DETERMINES FREQUENCY
Sampling Frequency Final Risk Score
Baseline 1‐2
Biennial 3‐5
Annual 6‐9
Semi‐Annual 10‐13
Quarterly 14+
Periodic Not Calculated
SAMPLING PLAN MATRIX
Department Job/Task Agent RawRisk
InitFreq n
Avg
%Limit Risk Score
(Monitoring)
Adjusted Risk
Adjusted
Frequency
FINAL
SAMPLING
FREQUENCY Last Sample Date
Next Sample Due
Date
Comments
Paint Line 1F Coater Operator Occupational Noise 9 Annual 10 36% 2 4.5 Biennial Biennial 10/13/2016 10/13/2018
Paint Line 1F Coater Operator Cumene 6 Annual 4 1% 1 6 Annual Annual 10/13/2017 10/13/2018
Paint Line 1F Coater Operator Methyl ethyl ketone 6 Annual 15 8% 3 2 Baseline Annual 10/13/2017 10/13/2018
Paint Line 1F Coater Operator Formaldehyde 6 Annual 19 18% 3 2 Baseline Semi‐Annual 10/13/2017 4/11/2018
Paint Line 1F Coater Operator Acetone 6 Annual 4 1% 1 6 Annual Periodic 12/8/2010
Paint Line 1F Coater Operator Xylene 0 Baseline 5 1% 1 0 Baseline Baseline 12/8/2010
Paint Line 1F Coater Operator Methyl isobutyl ketone 6 Annual 1 1% 1 6 Annual Annual 1/17/2008 1/16/2009
Paint Line 1F Coater Operator Heat Stress 4 Biennial 0 #DIV/0! #DIV/0! #DIV/0! #DIV/0! Baseline 1/0/1900
Paint Line 1F Coater Operator Cold Stress 4 Biennial 0 #DIV/0! #DIV/0! #DIV/0! #DIV/0! Baseline 1/0/1900
Most Recent Sample Date and Due Date Shown Here
Color codes indicate status of Plan. Red = Overdue, Yellow = due within 45 days, Blue = no samples
recorded
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IH RASP LIMITATIONS
• Does not account for PPE• Tracked in the spreadsheet, but not in the frequency calculation
• Does not account for employee workload or task‐based• Tracked in the spreadsheet, but not in the frequency calculation
• Errs on the side of more monitoring with a weak data set
TRENDING
Measured concentrations peaked in 2012,
prompting additional sampling
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HOW TRENDING CAN BE USED• Example: Sampling at Melt Deck Conducted every quarter for over 3 years
• Trending analysis showed steadily increasing concentrations
• Prompted additional Engineering Controls and concentrations were reduced
Engineering Controls
Introduced
CONCLUSION
• AN EFFECTIVE INDUSTRIAL HYGIENE PROGRAM
• Is based on a policy that is committed to from the top‐down
• Includes a written program
• Effectively manages data and explores trends
• Is pervasive throughout other company programs
• Is integrated into the facility’s culture
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Corporation Perspective
• First, find a consultant with the same values and understands your business.
• Second, ensure they have a team that can support your needs.
• This includes future needs
Managing IH
• How do you manage your IH?
• Do you have multiple sites?
• Who will be performing the work? • Consultant or company personnel?
• What is your goal?
• Do you have a time line?
• Do you have internal support?
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Database• Use some type of data base!
• Don’t just file your report but manage it.
Date Q Year Division Facility Consultant Shift TWA/TSK P/A/C Crew Sample ID
Total
Sample
Time
Name Dept.
2/1/2018 1 2018 Steel Anywhere, IN AAA Day TSK P A 5‐129785 480 John Doe Crane Crew
2/1/2018 1 2018 Steel Anywhere, IN AAA Day TSK A A 4‐267929 485 AREA Electric Arc Furnace
2/1/2018 1 2018 Steel Anywhere, IN AAA Day TSK P A 5‐129805 480 John Smith Electric Arc Furnace
You can see that certain percentages trigger a color.
Task/Job Agent < Conc. AL PEL TLV %AL %PEL %TLV
Cleaning Cranes Iron Oxide 1 N/A 10 5 N/A 10% 10%
In Front of Furnace During Rebricking Iron Oxide 5 N/A 10 5 N/A 50% 50%
Rebricking Furnace Iron Oxide 10 N/A 10 5 N/A 100% 100%
Risk Assessment Sampling Plan (RASP)• First off, we developed a RA from the AIHA guidelines from the: Strategy for Assessing and Managing Occupational Exposures.
• Determine if you need to audit your IH program. AIHA has a great book to help you (Industrial Hygiene & Safety Auditing: A Manual for Practice.
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Industrial Hygiene ‐ Health Hazard Exposure Assessment SheetPlant Location
Assessment Conducted by:Date of
Assessment: 1/1/2018
Review Conducted by:
Revised by (date):*J, Q, P, & C ‐ This column indicates whether the assessment was based solely on judgment (J), quantitative monitoring data (Q), the existence of a site‐specific program (P), or company imitative (C).
*n = number of samples collected
Enter the name of the Building
and then Department
Enter the Job Titles
or Classificati
ons
Enter the Tasks or Processes
List the chemical
substances or physical agents
List the name and
manufacturer of the
product or products that the chemical or substance is present in.
Has this chemical been given an A1 or SEN
designation by
ACGIH?
Enter value for each
substance or agent. Use
categories 1 to 5 (use OELs).
Enter for each
substance or agent. Use
categories 1 to 4. (see
matrix)
This is the "RISK RATING" for the
evaluated process or task (the
range of this
rating will be from 1 to 20)
Enter for each
substance or agent.
Use categories Very High,
High, Medium, Low or
Very Low. (See
matrix)
Enter for each
substance or agent.
Use categories J, Q, P, &
C. *
Frequency at which
monitoring should occur, if beyond Baseline. Enter
Baseline if no Qualitative data but
above "Very Low".
Include whether or not PPE,
administrative or
engineering controls are effectively used to mitigate exposure levels.
Comments for each substance or agent.
Also, include details of task and judgment if
included.
Enter range of data available for each task or job TWA = Personal
sampling data Ambient =
Area sampling data. Include reason for not including on sampling plan if additional data is not warranted.
Department Job Titles Process TaskMaterial or
AgentSource
Carcinogen or SEN?
Health Effect Rating
Exposure Category
Risk Rating
Monitoring Priority
Assessment
Method*
Sampling Frequency
Controls Comments
Exposure Monitoring Data (as of 12/1/2017)
MaintenanceAll
employees
Conducting maintenance
on production
floor, generating noise from handling
power tools, etc.
Noise
Power tools and
production equipment
NO 4 2 8 Medium Q Every 3 Years
Hearing Protection Devices
(HPDs) are required
Approximately twelve maintenance
employees work 12‐hour shifts in the department.
Employees work most of their shifts on the production floor, being exposed to process equipment noise. Additionally,
power tools and other machinery causes
noise. Noise exposure occurs all day every day at high levels.
n =1; the measurement was 84 dBA (80 dB) and 80 dBA (90 dB) and exceeded the OSHA AL of 82 dBA but was below the OSHA PEL
Sampling Plan• Now you have a RA, what are you going to do with it? IH Sampling Plan for XXX
Sampling Plan
Dept Job Class Process / Job Task Chemical Sampling FrequencyLast Sampling
DateResult (TWA or STEL)
Next Sampling Date
# of Employees
# of Samples
Maintenance All employeesConducting maintenance on production
floor, generating noise from handling power tools, etc.
Noise Every 3 Years 6/7/201684 dBA (80 dB) and 80 dBA (90 dB)
6/7/2019 12 5
*All of the listed information can be found in the AIHA Strategy for Assessing and Managing Occupational Exposures
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Managing SEGs
*All of the listed information can be found in the AIHA Strategy for Assessing and Managing Occupational Exposures
Statistical Tools
• First, Exposure Assessment Tools. • IH STAT‐FREE with AIHA Membership!
• https://www.aiha.org/get‐involved/VolunteerGroups/Pages/Exposure‐Assessment‐Strategies‐Committee.aspx
• IHDataAnalyst V1.33• https://www.easinc.co/ihda‐software/
• Free “student” for 1 year
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What Stats will tell you?• Statistics:
• Non‐parametric (order) statistics• Descriptive statistics• Compliance statistics• Non‐parametric compliance statistics
• Goodness‐of‐fit analysis• Subjective (graphical analysis)• Objective (formal statistical tests for goodness‐of‐fit)
• Bayesian Decision Analysis• Calculation of probability that the true exposure profile is in a specific AIHA exposure control category or an EU Hazard Band
• Appropriate class of respirator (i.e., Assigned Protection Factor)• Professional judgment can be explicitly factored into the calculations• Adjustment for censored (i.e., <LOD) data
• High resolution, customizable graphs• Report generator and editor:
System SoftwareIH STAT (Example)
Industrial Hygiene Statistics Data Description: Sample for Iron Oxide - Welding
OEL DESCRIPTIVE STATISTICS10.0 Number of samples (n) 14
Maximum (max) 15
Sample Data Minimum (min) 1(max n = 50) Range 14No less-than (<) Percent above OEL (%>OEL) 7.143
or greater-than (>) Mean 5.5005.0 Median 4.5007.0 Standard deviation (s) 3.8582.0 Mean of logtransformed data (LN) 1.4621.0 Std. deviation of logtransformed data (LN) 0.7578.0 Geometric mean (GM) 4.314
10.0 Geometric standard deviation (GSD) 2.1314.0
15.0 TEST FOR DISTRIBUTION FIT6.0 W-test of logtransformed data (LN) 0.9704.0 Lognormal (a = 0.05)? Yes2.08.0 W-test of data 0.9043.0 Normal (a = 0.05)? Yes2.0
LOGNORMAL PARAMETRIC STATISTICSEstimated Arithmetic Mean - MVUE 5.602
LCL1,95% - Land's "Exact" 4.059
UCL1,95% - Land's "Exact" 9.471
95th Percentile 14.976
UTL95%,95% 31.173
Percent above OEL (%>OEL) 13.325
LCL1,95% %>OEL 4.849
UCL1,95% %>OEL 29.753
NORMAL PARAMETRIC STATISTICSMean 5.500
LCL1,95% - t statistics 3.674
UCL1,95% - t statistics 7.326
95th Percentile - Z 11.847
UTL95%,95% 15.58
Percent above OEL (%>OEL) 12.173
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System SoftwareIHDataAnalyst V1.33 (Example)• Bayesian Decision Analysis.
Posterior
Exposure Rating0 1 2 3 4
Deci
sion
Pro
babi
lity
1
0.8
0.60.4
0.2
0
0 0 0
0.957 Posterior
APF1 10 50 1000 >1000
Deci
sion
Pro
babi
lity
1
0.8
0.60.4
0.2
0
0.043
0.957
0 0 0
BDA Charts PPE Charts
How to use statistics for decision making
• Use statistical tools to manage the removal of chemical programs
• You can use BDA decision making for engineering fixes.
• You can use 95%tile to determine risk and acceptable exposures.
• You can use the Geometric Standard Deviation to determine acceptable variability.
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Use Your Resources
• Use all your resources to make decisions:• Talk to people performing work (they know the details).
• Speak with engineering on what you are seeing (they can help guide you).
• Speak with other locations if possible to see if they are seeing the same thing as you are.
• Create a progressive plan that can be achieved by everyone on the team.
• A plan outlines what is to be accomplished so everyone knows the goal.
THANK YOU!!
Justin Hoover, MS, CSP
Industrial Hygienist
Corporate Safety Resources
7575 West Jefferson Boulevard
Fort Wayne, Indiana 46804
Andrew W. Boester, CIH
Senior Project Manager
SES Environmental
3807 Transportation Drive
Fort Wayne, Indiana 46818
260-497-7645