ctawwa health & safety training
TRANSCRIPT
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Spring 1501 - Health and Safety at Water Treatment Facilities
January 29, 2015
David P. Horowitz, P.E., CSP (@dphorowitz)Peter J. Grabowski, P.E.
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■ Health & Safety– OSHA Top 10
■ Globally Harmonized System– Changes
– Implementation Dates
■ General Water Treatment Plant Hazards■ Safe Chemical Handling
– Typical treatment plant chemistries
– Initial response activities
– Tanks
■ Chemical Feed System Design– Tips for success
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Safety Takeaways
■ Watch for common issues!
■ Watch your staff & contractors
■ Management of change
– Safety Data Sheets
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■ The most frequent injuries in water treatment facilities are:
a. Cuts and bruises
b. Explosive and toxic gases
c. Slips and falls
d. Strains and Sprains
e. None of the above
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I’m from OSHA. I’m here to help.I’m from OSHA. I’m here to help.
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#10 Electrical – Systems Design
■ Electrical design■ Arc Flash (NFPA 70E)
System specific evaluations
■ Proposed equipment■ Existing equipment
■ PPE
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#9 Machine Guarding
■ Engineered or structural fixes
■ Job Hazard Analysis (JHAs)
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#8 Electrical - Wiring■ Permanent■ Temporary
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#7 Ladders - CONSTRUCTION
■ Design considerations■ Milestone Observation
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OSHA Video - Ladders
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#6 Lockout / Tagout
■ System specific evaluation
■ Comprehensive energy source understanding
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#5 Powered Industrial Trucks
■ PIVs■ Hoisting requirements
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#4 Respiratory Protection
■ Engineer out, if possible■ Written Plan
■ Baseline physical■ Medical surveillance■ Fit testing
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#3 Scaffolding -
CONSTRUCTION
■ Design considerations■ Milestone Observation
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#2 Hazard Communication
■ Globally Harmonized System
■ Risk Management Planning– Chlorine Gas = >2,500 Lbs
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#1 Fall Protection - CONSTRUCTION
■ Design considerations■ Milestone Observation
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■ The most frequent safety hazard from the use of polymers is:
A. Attack on many types of stainless steel
B. Cause of severe burns and blindness
C. Evolution of a toxic gas
D. Extreme slipping hazard when spilled on surfaces
E. The boss scrutinizing chemical costs
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Global Harmonized SystemMajor Changes
■ Training and implementation■ Hazard classification■ Labels and warnings■ Standard Safety Data Sheets
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OSHA Video - GHS
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Hazard Classifications
Physical Hazards
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Hazard Classifications
HealthHazards
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■ The goal of GHS■ Label elements and GHS pictograms■ Labeling components■ Possible sources of confusion
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What’s wrong with HAZCOM
Too many systems
Too many systems Too confusingToo confusing
Too time consumingToo time
consuming Too nationally focused
Too nationally focused
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What’s wrong with HAZCOM?
Lots
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Sometimes the Signs Are Obvious
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Sometimes They Can Be Subject to Interpretation
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Or need an interpreter
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Or worse
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Bad stuff out there
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Protect yourself
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Protect others
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Major ChangesThe Basics
■ Hazard classification■ Labels and warnings■ Standard Safety Data Sheets■ Training and implementation
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GHS is the law
Turning a performance-based standard
Into prescriptive requirements
www.chinasmack.com
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Effective Completion Date Requirement(s) Who
December 1, 2013 Training•New Label Elements•Safety Data Sheets
Employers
June 1, 2015 Manufacturer full complianceHAZCOM plans updated
Chemical ManufacturersEmployers
December 1, 2015 Distribution Prohibitions for non GHS labels
Chemical Manufacturers, Importers and Distributors
June 1, 2016 Updates to program and training based on new hazard classifications
Employers
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Physical Hazard Health Hazard
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HAZARD TYPES■ Physical
– Unstable Chemicals (Water Reactive)
– Flammables or Combustibles
– Explosives
– Stored at High Pressures
– Thermal Effects
■ Health– Acute– Chronic– Latency Period
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PHYSICAL HAZARDS
■ May Cause Injury by Physical Action
■ Burns: Flammables, Combustibles
■ Pressure: Compressed Gasses
■ Explosions: Explosives, Reactives
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Hazard Classifications
Physical Hazards
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Hazard Classifications
Physical Hazards
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EXAMPLES: PHYSICAL HAZARDS
■ Flammable
■ Explosive
■ Oxidizer
■ Pyrophoric
■ Unstable (Reactive)
■ Water Reactive
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EXPLOSIVE
■ Sudden Release Of:– Pressure– Gas– Heat
■ When Exposed To:– Sudden Shock– Pressure– High Temperature
■ BLEVE: Boiling Liquid Expanding Vapor Explosion
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OXIDIZER■ Reacts With Organic Material
■ Releases Oxygen
■ Promotes Combustion
Sodium Hypochlorite
Peracetic Acid
Oxygen
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UNSTABLE (REACTIVE)
■ Unwanted Chemical Change During Normal Handling
■ May Generate– Heat– Pressure– Polymerization
■ Can Create– Fires– Explosions
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WATER REACTIVE
■ Presence of Water
■ Forms a Gas That Is:– Flammable or
– Toxic
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Flammable Liquid Categories
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Possibility for Confusion?Flashpoint
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200
NFPA / OSHA Flammable Combustible
NFPA 704 Diamond 4 3 2
EPA / DOT Flammable Combustible
GHS 1 or 2 3 4
Signal Word Danger Danger Warning
Hazard Statement
Extremely flammable liquid and vapor
Highly flammable liquid and vapor
Flammable liquid and vapor Combustible liquid
Pictogram Nothing
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Possibility for Confusion?
NFPA Video - Confusion
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Compressed Gasses■ Injurious due to
pressure
Ethylene Oxide
Oxygen
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HEALTH HAZARDS
■ Acute– Immediate Effects
■ Chronic– Effects May Build Over Time– May Be Latency Before Recognized Effects
■ Latency Period– Period Between Exposure and Exposure Effects
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OSHA Video - PELs
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Hazard Classifications
HealthHazards
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Hazard Classifications
HealthHazards
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ACUTE EXPOSURE / EFFECTS
■ Example: Acids
■ Body Recognizes on Immediate Exposure■ Can Get Prompt Medical Attention
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CORROSIVE■ A Hazardous Material That
Causes Visible Destruction Of, or Irreversible Alteration in Living Tissue at the Site of Contact
Sodium Hypochlorite
Sodium Hypochlorite Peracetic AcidPeracetic Acid
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Acutely Toxic – Low Hazard■ Acutely
– Effects are “immediate”■ Toxic
– Chemical that causes harmful effects
– To target organ(s)– Effects are different
depending on target organ
■ May be Systemic– Affects almost all target
organs
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Acutely Toxic – Low HazardIsopropyl alcohol
Isopropyl alcohol
DacarbazineDacarbazine
GlutaraldehydeGlutaraldehyde
AcetoneAcetone
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Acutely Toxic - Ir ritant■ A Hazardous Material That Causes a Reversible
Inflammatory Effect on Living Tissue by Chemical Action at the Site of Contact
Isopropyl alcohol
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Acutely Toxic – Sensitizer■ A Hazardous Material That Causes a Percentage of
the Exposed Group to Develop an Allergic Reaction After Repeated Exposure
Methyl methacrylate
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Acutely Toxic – High Hazard■ Acutely
– Effects are “immediate”■ Toxic
– Chemical that causes harmful effects
– To target organ(s)– Effects are different
depending on target organ
■ High Hazards– Effects are significant– May be immediately life
threatening Ammonia
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Chronic Toxic Effects■ Examples
– Carcinogens– Teratogens– Reproductive toxins
■ Health effects– Vary with chemical– Affect target organ– May not show up for
years after overexposure
Dacarbazine Glutaraldehyde
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Label Elements■ Sodium hypochlorite
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Label Elements
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Label Elements
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How to really confuse people
Turn thisTurn this
Into thisInto this
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Safety Data Sheets
■ Prescriptive requirements■ Sections must be consistent■ Information dictated by GHS guidance
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SDS Hazards Description
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SDS Sections
■ Section 1, Identification ■ Section 2, Hazard(s) ■ Section 3, Composition/information ■ Section 4, First-aid measures ■ Section 5, Fire-fighting measures ■ Section 6, Accidental release measures ■ Section 7, Handling and storage ■ Section 8, Exposure controls/personal protection ■ Section 9, Physical and chemical properties ■ Section 10, Stability and reactivity ■ Section 11, Toxicological information ■ Section 12, Ecological information■ Section 13, Disposal considerations■ Section 14, Transport information■ Section 15, Regulatory information■ Section 16, Other information, includes the date of preparation or last revision.
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What hasn’t changed
■ Exclusions and exemptions■ Elements of the HAZCOM program■ Training requirements■ Secondary container labeling■ Temporary container exclusion■ Special labeling systems
– NFPA 704– HMIS
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Effective Completion Date Requirement(s) Who
December 1, 2013 Training•New Label Elements•Safety Data Sheets
Employers
June 1, 2015 Manufacturer full complianceHAZCOM plans updated
Chemical ManufacturersEmployers
December 1, 2015 Distribution Prohibitions for non GHS labels
Chemical Manufacturers, Importers and Distributors
June 1, 2016 Updates to program and training based on new hazard classifications
Employers
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Conclusion
■ HAZCOM is adopting GHS■ Broad applicability – everybody is “in”■ Lots to do
– Training on GHS elements– Plans and programs need to be revised– SDS need to be developed– New labels need to be designed and implemented
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Safety Issues for Water Operators■ Confined Space
– Monitoring– Definition– PRCS– Procedures
■ Lockout/Tagout– Energy Control procedures– Locks & tags– Electrical exposure
■ Fire Safety/Extinguishers– A-comb; B-electrical; C-chemical– Safe storage of flammables
■ Safe Lifting– Sizing up the lift– Back braces– Two person lifts– Lifting aids (hoists)
■ Hazard Communication– Hazard types: physical/health– Health hazards: acute/chronic– NFPA 704/HMIS– MSDS
■ Chemical Safety Information– Caustics: corrosivity– Always add acid to water– Good ventilation
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Safety Issues for Water Operators■ Machine Guarding
– Power transmission– Guards & blocks
■ Walking/Working Surfaces– Housekeeping– Oils– Caustics– Ice– Ladders– Fall safety
■ Chemical Monitoring– Instruments– O2 deficiency– Combustible gas indicator– H2S
■ PPE– Safety glasses: a must!– Gloves: compatible material– Respirators– Hearing protection– Eyewashes/Showers
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Safety Issues for Water Operators■ Emergency Preparedness
– Emergency action plan– Take care of yourself first– Call postings– Evacuation procedures– Buddy system
■ Accident Prevention– Signs: caution, warning, danger– Labeling containers & tanks– Pipe colors
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Safe Chemical Handling and Initial Spill Response
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Objectives■ Specific water treatment chemical hazards■ Means of hazard recognition
– Normal handling– Spill / release situations
■ Evaluate Risk■ Protect yourself
– Use of personal protective equipment– Safe distance / places of refuge
■ Protect others
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Where to turn for hazard information?
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Safety Data Sheet■ Expanded Label
Information■ Accessible■ Provide Copies During
Emergency Response– Outside Agencies– Hospitals, on Injury
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Chemical Specifics■ Water Treatment
– Potassium Permanganate– Ferric Chloride– Liquid Oxygen– Aluminum Sulfate– Sodium Hypochlorite– Sodium Hydroxide– Sulfuric Acid– Chlorine
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Potassium Permanganate■ KMnO4
■ Warning: corrosive, oxidizer■ Routes: eye, skin, inhalation,
ingestion■ Symptoms: irritation, possible
chemical burns, pulmonary edema, managanism
■ Hazards– Strong oxidizer (avoid combustibles,
wooden pallets, acids)– Large quantities of dust presents
inhalation hazard– Chronic neurological effects
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Ferric Chloride■ FeCl3
■ Warning: corrosive, harmful■ Routes: eye, skin, ingestion■ Symptoms: skin irritation,
possible skin burns■ Hazards
– Slightly acidic depending on concentration
– Serious harm to eyes if splashed– Vomiting after swallowing– Large exposures cause cadiovascular
distress– Toxic on liver and kidneys
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Liquid Oxygen■ O■ Warning: gas under
pressure, oxidizer■ Additional: cryogenic liquid
causes frostbite■ Hazards
– Additional oxygen causes fires to burn more violently
– Frostbite can cause severe injury including loss of skin, fingers, etc
– Compressed gas cylinders can overpressure, causing explosions
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Aluminum Sulfate■ Al2(SO4)3
■ Warning: irritant■ Routes: eye, skin,
inhalation, ingestion■ Symptoms: irritation,
shortness of breath, vomiting, diarrhea
■ Hazards:– Avoid ingestion– Hydrolyzes in water forming
sulfuric acid
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Sodium Hypochlorite■ NaClO■ Warning: oxidizer, corrosive
(caustic)■ Routes: eye, skin, inhalation,
ingestion■ Symptoms: irritation, chemical
burns, blood disease on chronic overexposure
■ Hazards– Reaction could generate chlorine gas– Extremely slippery– Oxidizing will cause accelerated
burning
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Sodium Hydroxide■ NaOH■ Warning: corrosive
(caustic)■ Routes: eye, skin,
inhalation, ingestion■ Symptoms: irritation,
chemical burns, hair loss■ Hazards:
– Extremely slippery– Difficult to remove– Reacts with acids
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Sulfuric Acid■ H2SO4
■ Warning: corrosive■ Routes: eye, skin, inhalation,
ingestion■ Symptoms: irritation, chemical
burns, pulmonary edema■ Hazards
– Highly reactive / generates fumes– Inhalation effects may be delayed– Neutralization enhances the reaction– Adding water may not be effective
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Chlorine Gas / Liquid
■ Corrosive / toxic by inhalation– Vapors condense to form hydrochloric acid– Toxic at relatively low airborne concentration– Can cause pulmonary edema
■ Cryogenic as a liquid■ Reactives
– Ammonia and fuel gas– Explosive compounds
■ Strong odor, good warning properties
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Chemical Emergency Response
Now we really have a problemNow we really have a problem
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THREE C’s
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■ Actions– Remember your priorities– Separate personnel from the hazard– Assess risk– Respond within your capability– Notify the chain of command– Follow your Emergency Response
Plan
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Core Objectives
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Don’t get tunnel vision
■ Chemical– Physical hazards– Health hazards– Incompatibles– Ignition sources– Heat
■ Other hazards?
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Bad Things Usually Happen
Fires
Explosions
ToxicGases
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Acids Caustics
Sulfuric acidAluminum sulfate
Sodium hydroxideSodium hypochlorite
VS
Exothermic! Heat, fumes, spattering materials, pressure, fire
Incompatible Reactions
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Corrosive Oxidizer
Sulfuric acidAluminum sulfate
Sodium hypochloriteChlorine
Permanganate
VS
Heat, explosion, toxic gas (chlorine)
Incompatible Reactions
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Fuels/Solvents Oxidizer
GasolineDiesel fuel
Paint thinner
Sodium hypochloriteChlorine
Permanganate
VS
Violent reaction, heat, explosion
Incompatible Reactions
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Incompatible Reactions
Alcohols Corrosive
Methanol Sulfuric acidChlorine
VS
Heat, explosion
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KEYS TO SAFE RESPONSE
■ Discipline
■ Command
■ Management
■ Don’t Let Time Become
Your Enemy
■ Don’t Cut Corners
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Respond Within Your Capabilities■ First Responders –
Operations Level– Defensive containment– From a safe distance
■ Technician Level– Aggressive operations– Appropriate equipment and materials
are in-place
Annual refresher training required
Annual refresher training required
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Response Procedure
■ ER Coordinator ensures incident is properly reported– Local organizations– State environmental agencies– State health agencies
■ Communications coordinator to place internal organizations on standby– Responders– Supervisors– Quality control
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Actions At The Scene■ ER Coordinator
– Directs responders– Liaison to incident commander– Maintains records at the scene
■ Response– Based on threat to public safety
and treatment system
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Response To Threats To Public Safety
■ Actions– Inform appropriate internal organizations– Mobilize resources to the scene– Initiate containment activities to protect critical infrastructure– In concert with Incident Command
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Site Activities
■ Assessment of conditions■ Identify trapped or injured
personnel■ Ensure appropriate notification■ Isolate environmental receptors
– Water– Ground
■ Containment and curtailment■ Defensive measures
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Isolate Environmental Receptors
■ As far away as reasonably possible
■ Direction of spill migration■ Drains, doors, etc.■ Spills vs releases
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Site Conditions■ Do not contact spilled materials■ Illumination■ Heat■ Protrusions■ Physical activity■ Limited time■ Use of stairs and ladders■ Vision■ Communication
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Conclusions / Key Points
■ Employee responsibilities– Know the chemical hazards– Use controls to prevent exposure– Review MSDS / SDS during non-routine tasks– Take action if symptoms of overexposure are felt
■ Response– Know the 4 core objectives– Chemicals can behave very differently when out in the open– Don’t take anything for granted– Get away and get the right resources to the situation– Mistakes can be costly
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Storage Tank Update
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West Virginia News
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■ Tank Trouble– Elk River, WV
» 400,000 w/o water» January 10, 2014
– Laurens, SC» Mystery oil spill
– Belgrade, Montana» Tank fire
– Bryan, OH» Massive bird kill
Storage Tank Update
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Storage Tank Update
■ Typical Tank Uses– Fleet fueling– Facility heating– Generator fueling
■ Underground Tanks– USTs– Fuel tanks need operators
■ Aboveground Tanks– ASTs– Receiving scrutiny
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Remote Spill Box/FillFuel Dispenser
Fuel Pump
Interstitial Leak Detection
Spill Kit
Normal Vent
Labels
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Dispenser Hose Bollards
Secondary Tank Emergency Vent
Primary Tank Emergency Vent
Mechanical Gauge
Preventive Limiting Barrier
Concrete Pad
1.5-inchesNut
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Integral Containment
Rain Shield
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Ideal Installation – Generator Tank
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What’s the best way to respond to a spill?
PREVENT IT FROM HAPPENING!!
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Common Chemical Uses
■ Coagulation■ Filter and Floc Aids■ Taste and Odor
Control■ Disinfection■ pH Adjustment■ Fluoridation■ Corrosion Control
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Chemical Feed System Designs■ Good Engineering
Practices– Regulatory Agencies– Utility Standards– Operator Preferences– Economics– Spatial Constraints
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Design Considerations/Flexibility
■ Bulk Tanks■ Transfer Pumps■ Day Tank■ Metering Pumps■ Containment
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Chemical Compatibility■ ALWAYS check wetted material for
compatibility■ Effect Ratings
– None – excellent– Minor – good– Moderate – fair– Severe – not recommended
■ Resistance Charts
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Delivery Area Containment
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Bulk Tank Sizing■ Typical Sizing
– Avg. dosage– Max. flowrate– 30 to 45 days
■ Chemical Stability
■ EPCRA
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Bulk Tank Options/Appurtenances
■ Number of Tanks■ Monitoring
– Automatic level indication– Visual sight tube
■ Discharge Motorized Valve
■ High Level Alarm/Audible Horn
■ Filter Canister
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Transfer Pump Design Considerations
■ Fill Time■ Flooded Suction■ Compatible Material■ Viscosity of the
Chemical■ Siphoning
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Day Tank Options/Appurtenances
■ Electronic Load Cell
■ Sight Tube■ Automatic Level
Indication■ High Level Switch■ Remote
Monitoring
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Metering Pump Design
■ Concentration■ Specific gravity■ Viscosity■ Temperature■ Suction Lift or
Flooded Suction■ Injection
Pressure
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Chemical Feed System Operation
■ Best Management Practices
■ Standard Operating Procedures
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Secondary Containment
■ Concrete Berms with Coating
■ Secondary Containment Pallets
■ Fabricated Containment Systems
■ 110% of Largest Bulk Tank
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Chemical Fill Connections
■ PE Buckets■ FRP Enclosures■ PE Enclosures
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Containment Options
■ Coating System– Engineering fabric– Mil thickness
■ Fill Containment■ Sump with Pump■ Sump with Float Switch■ pH Neutralization System
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Safety Takeaways
■ Watch for common issues!
■ Watch your staff & contractors
■ Management of change
– Safety Data Sheets
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Questions
David P. Horowitz, P.E., CSPPeter J. Grabowski, P.E.
Tighe & Bond53 Southampton Rd.Westfield, MA 01085
Tighe & Bond177 Corporate Drive
Portsmouth, NH 03801603-433-8818
l446 Main Street
Worcester, MA 01605508-754-2201
l4 Barlows Landing Road, Unit #18
Pocasset, MA 02559508-564-7285
l213 Court Street, Suite 900
Middletown, CT 06457860-704-4760
l1000 Bridgeport Avenue
Shelton, CT 06484203-712-1100