Batch Plant Safety These handouts and documents with attachments are not final, complete, or definitive instruments. This information is for guidance purposes only. You should independently verify and satisfy yourself as to its accuracy. The AHBSIF does not assume any liability for damages arising from the use of this information or exhibits and attachments thereto and renders no opinion that any of the terms, conditions, and/or cited federal standards in this document and the exhibits and attachments should be explicitly followed by the fund member. Seek specific guidance from the appropriate regulator (OSHA) or professional advisor.

Contents The following information is to serve as a guide for creating a comprehensive safety program for batch plant operations. This information will address the following: – Dust Exposures – Noise Exposures – Point of Operation/Transmission Guarding – Housekeeping – Maintenance (Lock-out/Tag-out) – Materials Handling – Hazard Communication – Emergency Procedures

Dust Exposure Poses a threat to the eyes and lungs. Contributes to poor visibility, a common factor in work traffic incidents. Typically generated by the following operations: – Machinery working around stock piles – Cold bin operations – General yard traffic

Noise Exposures Prolonged exposure to excessive noise levels associated with the process can contribute to hearing loss. Noise is distracting and can interfere with audible communication.

Point of Operation/Transmission Guarding All pulleys, belts and drive mechanisms should be covered and protected. Moving belts, motors, chain drives, and other forms of transmission potentially accessible to employees must be considered for guarding. Loose clothing should never be worn at a plant.

Housekeeping Essential for plant safety. The yard and any other common traffic paths must be kept free of obstacles. Standing water poses potential hazards. Power source for all phases of the process must be maintained.

Maintenance (Lock-Out / Tag-Out) Manufacturer’s inspection and replacement intervals on all process machinery. Power transmission disconnected for all such operations. Established Lock- Out/Tag-Out Procedure.

Materials Handling Fleet Maintenance – Pre-shift inspection – All safety devices operational – Maintenance records up to date and complete Operator Training Traffic Patterns Bin collection samples

Hazard Communication Written Program Contains information on how the employer will meet the requirements of the standard Labeling Labels must include information such as the name of the material, manufacturer’s name and address, and hazard warnings (SDS) Safety Data Sheets Contain all important information on a material and must be accessible to employees at any time Employee Training Employees learn the characteristics of the materials

Written Plan A Written Plan must address the following issues; Procedures Related Safety & Health Issues Training Chemical Inventory Labeling Procedures

Labeling – The NFPA Placard Fire Hazard 4 – Below 73°F 3 – Below 100°F 2 – Above 100°F 1 – Above 200°F 0 – Will Not Burn Health Hazard 4 – Deadly 3 – Extremely Dangerous 2 – Hazardous 1 – Slightly Hazardous 0 – Normal MaterialReactivity 4 – Detonate 3 – Shock and Heat may Detonate 2 – Violent Chemical Change 1 – Unstable if Heated 0 - Stable Specific Hazard ACID – Acid COR – Corrosive OXY - Oxidizer The placard is used on all storage tanks and transfer containers (gas cans, storage vessels) O

Labeling Identifier 1 Pictograms 2 Signal words 3 Hazard Statement 4 Precautions 5 Supplier Identification 6

Labeling It is the employer’s responsibility to ensure that all containers of hazardous substances in the workplace are labeled Never remove a label Container size is irrelevant, all containers must be labeled The only labeling exception is “Immediate Use”, employee has 100% control of material.

Employee Training Employees must be trained on every new chemical in which they come in contact Acute and chronic health effects Proper handling and use Proper storage Clean-Up procedures Proper disposal Accessing information (SDS Manual)

Hazard Communication Checklist Inventory of Chemicals UsedMatch Chemicals With Exposures Obtain all SDSSafe Work Practices for Each Chemical Identify SDS Storage LocationEmployees Educated on Potential Exposures Employees Know Location of SDS Employees Trained on Use of Material All Containers LabeledNotify Other Contractors When Necessary

Emergency Procedures Emergency Evacuation plan Fire Safety Basic First Aid

Are you Prepared? Does the facility have a first aid kit? Are emergency contact numbers readily available? Do any of your employees/co-workers have CPR or First Aid training? Does the facility have an evacuation procedure?

Emergency Evacuation Plan Employees must be educated on all emergency evacuation plan specifics Exit map must be conspicuously posted Ensure primary and secondary routes are unobstructed Assemble outside the facility at pre-determined area for a head count Identify who is responsible for head count Identify who is responsible for emergency power shut down Identify who will make appropriate emergency phone calls No one reenters facility until emergency is over

Fire Safety Good house keeping is key to preventing fires - Do not use compressed air to blow sawdust - Keep evacuation routes/exits clear - Clean up daily

Fire Safety Develop a system to alert employees in the event of a fire Ensure exits are properly marked (steel roll up doors are not acceptable as fire exits) Ensure adequate number of extinguishers for size of building (no more than 75 ft. of travel) Ensure employees know extinguisher location Train employees on proper operation of extinguishers

Fire Extinguishers Fire extinguishers must be selected and provided for the types of materials in areas where they are to be used Class A, Ordinary combustible material fires. Class B, Flammable liquid, gas or grease fires. Class C, Energized-electrical equipment fires. Fire extinguishers should be mounted within 75 feet of outside areas containing flammable liquids, and within 10 feet of any inside storage area for such materials Access to extinguishers should be free from obstructions or blockage Fire extinguishers must be serviced, maintained, and tagged at least once a year

Extinguishers Ordinary Combustibles Includes materials such as wood and paper Flammable Liquids Includes fuels, grease, other liquids Electrical Fires Contains non-conductive smothering agent

Fire Extinguisher Inspection Body of the extinguisher; rust, cracks, dents Check hose for cracks, dry- rot All fittings snug, no signs of leaks Lever and hinge assembly Safety pin in place, safety tie present Inspection tag, present and up to date Pressure gauge, needle in the green

How to use a Fire Extinguisher P-A-S-S Pull -- Pull the pin at the top of the extinguisher that keeps the handle from being activated Aim -- Aim the nozzle at the base of the fire Squeeze -- Maintain a distance of eight to ten feet away from the fire and squeeze the handle. Discharge will only occur if the handle is being squeezed. Sweep -- Sweep the nozzle back and forth at the base of the fire until it appears to be out.

Basic First Aid The OSHA First Aid standard (29 CFR ) requires trained first-aid providers at all workplaces of any size if there is no “infirmary, clinic, or hospital in near proximity to the workplace which is used for the treatment of all injured employees.”

Handling an Emergency The three C’s, Check, Call, Care help us remember what to do in an emergency situation.  Check – check the area for your own safety first, then the victim's  Call – for help, 911 or whom ever is in the immediate area that can provide assistance  Care - administer care to the victim, this may be first aid or at least stabilization