Transcript Mechanical Systems Inc. Safety Training

New Hire Orientation
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Safety Policy, Roles, and Disciplinary action
Lock-out Tag-out (LOTO)
Hearing Conservation (HCP)
Respiratory Protection (RPP)
Hydrogen Sulfide (H2S)
Benzene (C6H6)
Lead (Pb)
Naturally-Occurring Radioactive Material (NORM)
Bloodborne Pathogens (BBP)
First Aid and Emergency Response (FA & ER)
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It should be noted that all the topics contained in the training
are premised by two factors:
 Meetings prior to the start of work between the Foreman,
Site Supervisor, or Safety Consultant and the client’s Plant
Manager or Safety Director to determine existing
conditions, safety programs used by the client, and results
of past air monitoring
 Site and air quality assessments by either our Foreman or
Safety Consultant prior to the start of work to determine
which program elements need to be implemented to
protect the safety and health of our workers
NO JOB OR TASK IS SO IMPORTANT THAT IT
CANNOT BE DONE SAFELY
Any violation of safety policy or program, including
not wearing required PPE (or wearing incorrectly),
using incorrect tools or equipment, or general
horseplay or “sloppiness” in work will be punished
 Worker safety behavior will be considered in all
performance reviews and promotions
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Foremen and Site Supervisors are required to
observe all work behavior, and act accordingly to
correct/discipline people
 Workers are expected to follow all safety and work
rules, and remind each other
 If a Foreman or Site Supervisor is not conducting
themselves properly or allowing unsafe behavior to
exist, that worker is required to report it to HSSE.
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First offense: written warning, copies to employee’s
personnel file.
 Second offense: written warning, suspension for ½
or full day without pay.
 Third offense: written warning, suspension for three
days without pay and/or immediate termination.
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 Not wearing PPE when required.
 Horseplay.
 Unsafe work habits.
 Violations of other safety rules/regulations.
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Three or more safety violations of the same type.
General overall record of unsafe practices.
Refusal to follow safety guidelines or instructions.
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Theft of Property
Willful damage or mutilation of company or client
property.
Possession of Firearms or weapons on site.
Sleeping on the job.
Under the influence or possession of drugs or alcohol
on site.
Refusal to accept work assignment.
Fighting.
Gambling.
Absence of two consecutive days without proper
notification.
Gross insubordination.
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Horseplay
Violation of safety rules.
Failure to report job related accident or injury.
Unsatisfactory work.
Excessive tardiness.
Willful delay of production.
Protection against energy or accidental release of energy while performing
maintenance work
In the course of your work, you will encounter
equipment or machines that need to be “shut
down” to prevent the release of energy while
working
 Program will provide a basic overview of:
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Recognition of hazardous energy sources
Determination of magnitude of energy
Devices and means for isolating/controlling energy
Limitations on the use of “tags” when locks cannot
be used
 Purpose and use of energy control procedures
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NOTE: Job-specific retraining will be conducted
onsite, as new or unfamiliar equipment is
encountered
The most prominent energy form you will encounter
is electricity, which can cause electrocution or
accidental equipment start-up
 Other forms of hazardous energy that could cause
injury or accidental equipment startup:
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 Pneumatic (pressurized gas)
 Steam (super-heated water)
 Hydraulic (pressurized liquid)
 Tension (spring or other stored mechanical energy)
 Potential (weight at a height, gravity provides energy)
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Foreman and Site Supervisors will be responsible for
determining the sources and magnitude of energy.
They will meet with the Plant Manager, Safety Director,
or Maintenance Manager prior to the start of work to
create and approve LOTO procedures and checklists
 For electrical equipment, the power magnitude is available at
the circuit breaker, sub-panel, or placard where line enters the
machine.
 For pressurized lines and systems, either a gauge or placard on
the machine will indicate magnitude
 For tension and potential energy in equipment, a placard or
manufactures manual will indicate magnitude of stored
energy.
“Locking out” means turning off power sources
and using a lock to prevent anyone from turning
the power back on.
 Under special circumstances, it may be impossible
to either shutdown an entire process, or effective
place a lock on a switch or valve.
 Under those circumstance, a tag will be affixed to
the “off” point, describing the need for this switch
or valve to remain off, date/time it will likely be
turned back on, and who is conducting the work.
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Each project crew will be assigned a set of locks and tags.
Only the Foreman or Site Supervisor will retain the keys, as
they are the only ones authorized to inspect a job and make
the decision to remove a lock or tag.
For valves, levers, buttons, switches, and other equipment
not equipped with a lock-hold, special molded covers will be
obtained to prevent access once it has been closed, and that
cover will be locked.
Only where locks or molded covers cannot be used may tags
be used to inform people that a valve, lever, button, or
switch should not be opened or activated because of work
being done on the equipment. This is the least effective
means to protect workers from energy and accidental
activation. The Tag will ID the Forman/Supervisor.
For each project, prior to the start of work the Forman or
Site Super will meet with the Plant Manager, Safety
Director, or Maintenance Manager to determine which
equipment will need LOTO procedures, and create a
checklist for controlling and isolating energy sources.
 The Forman or Site Super will be required to obtain the
necessary locks and covers to complete the LOTO
procedures, and train their work crew on the location of
energy sources and how those sources will be controlled.
 The Forman or Site Super will oversee the isolating of
energy and locking/tagging. Once complete, they will also
be responsible for activating the equipment to verify energy
was isolated and remove any stored energy.
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In some cases, the energy may need to be returned
prior to completion of the job. In these situations,
the Forman or Site Supervisor will do the following
before re-activation:
 Clear away all tools, equipment, and people
 Remove the LOTO device(s)
 Energize equipment/system and conduct test of
function, while having a look-out worker “at ready”
to deactivate if Foreman or Site Super finds
something wrong while conducting the test
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Before work may proceed on the job, the full
LOTO procedure/checklist must be completed
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At the completion of each job, the Foreman
and Site Supervisor will review the
effectiveness of the LOTO procedures and
checklists used.
 If any defect or discrepancy is identified, they
should discuss it with the Plant Manager, Safety
Director, or Maintenance Manager
 If procedures and checklists were effective, then
they should be retained for future use, and
submitted to the Safety Consultant for review
and addition to the training program
Protection of hearing ability through noise monitoring, education, personal
protective equipment, and audiometric testing
The National Institute for Occupational Safety and
Health (NIOSH) contends that occupational
hearing loss is “100% Preventable”
 MSI employees will be trained on the hazards
associated with noise, how to select and use
hearing protection, and responsibilities for
employees covered by the hearing conservation
program
 All hearing protection costs associated with the
hearing conservation program will be covered by
MSI.
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Noise amplitude is measure in (decibels),
which reflect the “sound pressure”.
 The greater the amplitude, the louder the noise,
and the more energy absorbed by the ear.
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Your outer ear collects sound from your
environment and channels it into the ear
canal, where cilia (tiny hairs) and inner ear
transmit sound energy to mechanical energy
to electrical signals to the brain (where we
interpret sound).
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Hearing loss comes from physical damage
to the ear, ear disease or infection, and old
age
If exposed to high amplitude sound for a
lengthy period of time, the cilia will become
damaged and no longer transmit signals,
resulting in “ringing” (tinnitus)
 If removed from noise, cilia can recover
 If continuously exposed (above 90 dB) or
exposed short-term at a level above 140 dB,
then the damage can be permanent
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“Ear muffs” or “ear plugs” dampens the sound
energy, and allows a lower energy to reach the inner
ear
Hearing protection is given a “noise reduction
rating” or NRR, as an indication of its noise
dampening ability
 For example, if you were exposed to a noise level of 105
dBA and wore ear plugs with NRR=30, then OSHA
would say you were being exposed to: 105-(30-7)= 82
dBA
However, hearing protection doesn’t work if you
don’t take care of it and use it properly
 MSI will cover all costs associated with hearing
protection and administration of the hearing
conservation program
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OSHA states that anyone exposed to a “time
weighted average” (not to exceed 130 dBA) over 90
dBA must wear hearing protection and covered by
the hearing conservation program (HCP)
Participants in the HCP are required to get a
baseline audiometric test, and annual tests
thereafter.
A permanent hearing loss of 15 dBA is called a
“standard threshold shift”, and is recordable as a
workplace illness (and requires follow-up)
Through worksite noise assessments, annual
audiometric testing, training, and proper use of
hearing protection, you can protect your hearing
ability
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Any employees exposed to over 85 dBA for
an 8-hour TWA will be included in the hearing
conservation program
The program consists of:
 Baseline and annual audiograms to track any
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changes in hearing ability
 Required use of hearing protection
 Annual training on hazard associated with noise
and proper use and care of hearing protection
Employees who experience a standard
threshold shift in hearing, will be notified of
the result and given special attention to
reduce work exposure to noise
Protecting worker health and safety via respirators when engineering controls
are unable to keep airborne contaminants below permissible exposure levels
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When hazardous gasses, vapors, fumes, and airborne
particulate cannot be controlled through ventilation
or filtration, then workers must wear respirators to
filter the air or provide safe air for breathing.
This training session will cover:
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When respirators must be worn
How to determine the proper respirator
What type of “medical clearance” respirator users need
Fit testing
How to inspect, clean, don, doff, and seal-check a
respirator
 How often you will need re-evaluation and re-training
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MSI will attempt to control airborne hazards with
ventilation and filtration (e.g. during welding,
cutting)
Air monitoring will be conducted on a regular basis
to assess ambient levels and personal exposure
If results indicate workers are exposed near or above
an OSHA permissible exposure limit (PEL), then
employees will be required to wear respirators that
either filter-out (or absorb) the air contaminant, or
in extreme cases, provide safety breathing air on its
own (e.g. air line or SCBA)
MSI will cover all costs associated with this program
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The first step in determining the proper
respirator is to determine the air contaminant
and assess worker exposure
 For air-purifying respirators (APR), need to select
the cartridge capable of filtering out
contaminant(s)
 If exposure exceeds the APR’s protection factor,
then safe breathing air must be supplied via an air
line or tank (SCBA)
 If the contaminant is an eye irritant, then a fullfaced respirator is needed (supplied air is normally
full-faced)
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Anyone who may need to wear a respirator
must first be cleared by a Physician to be
physically capable of safely wearing one
 Wearing a respirator places greater stress on the
respiratory system
 SCBAs and full-faced airline respirators are heavy
and demand greater physical condition
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MSI employees will undergo a pulmonary
function test, and complete a medical
questionnaire in order to be medically-cleared
to wear a respirator
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All workers who are medically-cleared to wear
an APR, will be fit tested with a half-faced
mask
 No beards or facial hair are allowed because the
prevent a seal between the respirator and skin
 Employees will undergo annual fit testing, using
the qualitative “irritant smoke” while performing a
battery of movements while iterating the rainbow
passage
 Employees who fail the fit test (after several
attempts) will be given a different model and
retested
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You must keep your respirator clean and in
good working condition
 Use alcohol wipes in the field to clean the inside
 Store your clean respirator in a bag or “sealable”
container
 Inspect the intake covers and exhaust cover for
proper fit and condition
 Inspect straps for condition and function
 When you return home from job, disassemble your
respirator and wash it with soap and water
For air-purifying respirators, you will need to use
the proper cartridge for removal of the identified
air contaminant
 Some cartridges are equipped with a colorimetric
box indicating “capacity”
 Based on exposure monitoring and published
capacities of the cartridges, your safety consultant
will be able to identify a change schedule
 Otherwise, if you ever detect an odor to symptom
related to the air contaminant, you are instructed
to leave the work area and report to either the
Foreman or Safety Consultant for respirator
inspection and site assessment
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Technical terms for “putting on” and “taking
off”
 To “put on” your respirator, first place the face piece
properly on your face then “clip” the top strap and
tighten, then “clip” the bottom strap and tighten
 To “remove” your respirator, just do the reverse
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To check the seal of your respirator:
 Negative check: cover the cartridges with the palms of
your hands and breathe in and hold it.
▪ Did the face piece “suck in”? Then you have a seal.
 Positive check: cover the exhale port with the palm of
your hand and breathe out.
▪ Did the face piece “bulge out”? Then you have a seal.
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If you fail, remove, inspect, re-doff, and retest the seal
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You will receive training annually, along with
updates/corrections identified while
administering the program in the field
You will need to complete a medical
questionnaire annually, and only receive a PFT
when required by the Physician
Annual fit testing will coincide with training
At any point during the year, anyone who
loses/gains a lot of weight or experiences a
change in face structure will need to undergo
fit testing and evaluation
Education on how to recognize, evaluate, and avoid
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Hydrogen sulfide is a highly toxic and flammable gas.
Because it is heavier than air it tends to accumulate at
the bottom of poorly ventilated spaces. Although very
pungent at first, it quickly deadens the sense of smell, so
potential victims may be unaware of its presence until it
is too late.
Where can you find H2S:
 byproduct of the petroleum, viscose rayon,
rubber, and mining industries.
 Organic decomposition of sulfur compounds in
sewers, barns, ships' holds, and sulfur springs
 The petroleum industry is responsible for most
cases of H2S toxicity in North America.
Hydrogen sulfide is considered a broad-spectrum poison,
meaning that it can poison several different systems in the body,
although the nervous system is most affected.
 The toxicity of H2S is comparable with that of hydrogen cyanide.
It forms a complex bond with iron in the mitochondrial
cytochrome enzymes, thereby blocking oxygen from binding
and stopping cellular respiration.
 Since hydrogen sulfide occurs naturally in the environment and
the gut, enzymes exist in the body capable of detoxifying it by
oxidation to (harmless) sulfate. Hence low levels of sulfide may
be tolerated indefinitely. However, at some threshold level, the
oxidative enzymes will be overwhelmed.
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Exposure to lower concentrations can result in eye irritation, a sore
throat and cough, shortness of breath, and fluid in the lungs. These
symptoms usually go away in a few weeks. Long-term, low-level
exposure may result in fatigue, loss of appetite, headaches, irritability,
poor memory, and dizziness.
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0.0047 ppm is the recognition threshold, the concentration at which 50% of
humans can detect the characteristic rotten egg odor of hydrogen sulfide
10-20 ppm is the borderline concentration for eye irritation.
50-100 ppm leads to eye damage.
At 150-250 ppm the olfactory nerve is paralyzed after a few inhalations, and
the sense of smell disappears, often together with awareness of danger,
320-530 ppm leads to pulmonary edema with the possibility of death.
530-1000 ppm causes strong stimulation of the central nervous system and
rapid breathing, leading to loss of breathing;
800 ppm is the lethal concentration for 50% of humans for 5 minutes
exposition
Concentrations over 1000 ppm cause immediate collapse with loss of
breathing, even after inhalation of a single breath.
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Using a 4-gas confined space meter, hydrogen
sulfide levels will be monitored throughout the
shift
When airborne levels reach 20 ppm (OSHA
Ceiling PEL), employees will be instructed to
wear full-faced APR respirators
If airborne levels reach 100 ppm (OSHA IDLH
Level), employees will be instructed to leave the
work area, and can only return if wearing an
airline with rescue tank or SCBA with full face
piece
If at any time, a person wearing an APR smells
“rotten eggs”, they will need to leave the work
area to acquire new respirator cartridges or to
conduct a seal-check
Education on how to recognize, evaluate, and avoid
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Benzene is an aromatic hydrocarbon (sometimes
called a volatile organic compound or VOC) that is
produced by the burning of natural products. It is a
component of products derived from coal and
petroleum and is found in gasoline and other fuels.
Research has shown benzene to be a carcinogen
(cancer-causing). With exposures from less than five
years to more than 30 years, individuals have
developed, and died from, leukemia. Long-term
exposure may affect bone marrow and blood
production. Short-term exposure to high levels of
benzene can cause drowsiness, dizziness,
unconsciousness, and death.
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Liquid at standard temperature and pressure, but its
volatility causes rapid vaporization, making it respirable
Smells like a “solvent”, and for years was used as a
common degreaser or used to clean oil-based paint
Has very low OSHA exposure limits:
 PEL: 1 ppm for 8-hour TWA
 STEL: 5 ppm for 15-minute TWA
However, the final OSHA Benzene standard in 1910.1028 applies to all
occupational exposures to benzene except some subsegments of industry where
exposures are consistently under the action level (i.e., distribution and sales of
fuels, sealed containers and pipelines, coke production, oil and gas drilling and
production, natural gas processing, and the percentage exclusion for liquid
mixtures); for the excepted subsegments, the benzene limits in Table Z-2 apply
(i.e., an 8-hour TWA of 10 ppm, an acceptable ceiling of 25 ppm, and 50 ppm
for a maximum duration of 10 minutes as an acceptable maximum peak above
the acceptable ceiling).
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Exposure Routes: inhalation, skin
absorption, ingestion, skin and/or eye
contact
Symptoms: Irritation eyes, skin, nose,
respiratory system; dizziness; headache,
nausea, staggered gait; anorexia,
lassitude (weakness, exhaustion);
dermatitis; bone marrow depression;
[potential occupational carcinogen]
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When Benzene is suspected to be present, the
Foreman or Site Supervisor will conduct air
monitoring to assessment ambient levels
All effort will be made to either control the
release through work methods
If Benzene cannot be contained, ventilation
will be used to remove it from the work area
If Benzene still exists in the work environment,
workers will be required to wear “coveralls”
(Tyvek suits), gloves, and full-faced respirators,
APR at low levels with VOC cartridges, or
airline+escape tank or SCBA at higher levels
Education on how to recognize, evaluate, and avoid
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Lead is a poisonous metal that can damage
nervous connections (especially in young
children) and cause blood and brain
disorders. Long term exposure to lead or its
salts (especially soluble salts or the strong
oxidant PbO2) can cause nephropathy, and
colic-like abdominal pains
Lead “accumulates” in humans, so
exposures must be limited to prevent future
illness caused by long-term exposures
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The OSHA PEL (8-hour TWA) is 0.050 mg/m ; the OSHA PEL (8hour TWA) for lead in "non-ferrous foundries with less than 20
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employees" is 0.075 mg/m .
 IDLH is 100 mg/m
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Exposure Routes inhalation, ingestion, skin and/or eye contact
Symptoms: weakness, exhaustion, insomnia, weight loss,
constipation, abdominal pain, colic; anemia; tremor; paralysis
wrist, ankles; kidney disease; irritation eyes; hypotension
 At low levels, a full-faced APR can be used (up to 0.5 mg/m3);
above 0.5, only supplied air line+escape tank or SCBA is used
If airborne lead is present, full-shift personal
sampling is needed to determine if exposure is
above the OSHA “action level” of 0.03 mg/m3 for
an 8-hour TWA (regardless of respirator use)
 Employees are required to receive personal
monitoring results within 15 days of receipt
 If a worker is found to be exposed above the action
level for more than 30 days per year, they will be
included in the medical surveillance program
 All effort will be made to control airborne lead via
engineering controls
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Engineering controls for reducing or
eliminating airborne lead include:
 Articulating hood entrapment, with a lead
collection filter
 Ventilation line that exhaust to a safe exterior port
 Fans or blowers that force fumes away from
workers and work area
Work coveralls will be provided and remain
onsite to keep lead contamination at the
worksite
 The use of respirators for controlling exposure
to airborne lead will only be used as an interim
solution until an engineering control can be
designed and implemented.
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Education on how to recognize, evaluate, and avoid
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The rocks that contain oil and gas deposits often contain water
as well. The water dissolves minerals and radionuclides, such as
radium, that are in the rocks. (These Technology Enhanced
Naturally Occurring Radioactive Materials are commonly
referred to as, TENORM.) Radium and other radionuclides and
their radioactive decay products become concentrated in
production wastes:
 pipe scale that tends to form inside oil and gas
production pipes and equipment, and sludge that
accumulate in tanks or pits.
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Field surveys have shown that petroleum pipe scale may have
very high Ra-226 concentrations, in some cases more than
400,000 pCi/g. Some of this waste is retained in oil and gas
production equipment.
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The concern is the possible inhalation and/or
ingestion of scale particles contaminated with
radium-226 and possibly other radioactive material
that may become airborne during welding, cutting
or reaming of pipe containing the radioactive scale.
If a contract calls for work on lines or vessels that
may contain TENORM, “badge” personal dosimetry
testing will be conducted to establish exposure
levels.
Until exposure levels are established, any work
performed on or around TENORM suspected
equipment will require hood-collection and HEPAfiltration, along with APRs and coveralls.
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When TENORM is suspected, all welding
and cutting fumes will be collected using a
ventilation system
Workers will also be required to wear a fullfaced APR with HEPA filter and coveralls
All debris and piping suspected to contain
TENORMs will require special disposal
using county and state radioactive waste
guidelines
Education on how to recognize, evaluate, and avoid
Some of the more common blood borne
pathogens are: human immunodeficiency
virus (HIV), hepatitis B virus (HBV), hepatitis
C virus (HCV), and others
 Most BBPs are passed through accidental
“needle sticks” of healthcare workers by an
infected syringe needle
 Although your risk is low, it is advantageous
for everyone to receive awareness training
on BBP hazards and how to avoid exposure
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It is highly recommended to treat ALL blood
and bodily fluid as contaminated, and
practice “Universal Precautions” whenever
you come into contact with blood, bodily
fluid, or human-based waste
 Universal precautions call for gloves, face
masks, and eye protection to prevent blood
droplets from entering your blood stream
 For administration of mouth-to-mouth CPR,
a mouth piece should be used, and alcoholbased wipes should on hand to disinfect any
contaminated equipment
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Foreman and workers who are Red Cross CPR
and First Aid certified will receive specialized
training on blood borne pathogens
The First Aid program will detail the
equipment and materials required for each
field kit to protect first responders in the case
of an accident
Awareness, responsibilities, and required supplies
In case an accident occurs on a job, MSI is requiring
that medical services be readily available
 Prior to the start of any project, the Foreman or Site
Superintendent will check for 9-1-1 availability,
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 If 9-1-1 cannot be used, the nearest hospital needs to be
identified, acquire their direct phone number, and a map
showing the most direct route to the hospital from the
job site
Each work team will have at least one person
certified in CPR and First Aid
 Each work team will be assigned a weatherproof first
aid kit and portable eyewash station (if they will be
working around corrosive or caustic materials)
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The portable and weatherproof case will
contain all the required medical supplies as
specified by ANSI Z308.1-2003
 When workers have the potential for
exposure to corrosive liquids with pH below 2
or above 12, and a plumbed eyewash station
is not within 100 feet, then a portable
eyewash station capable of providing 15minutes of eye flushing will be provided
(ANSI Z358.1)
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Everyone must sign the training sheet to receive credit for attending this
training course