Chemical Process Safety: Government Responsibility & Industrial Hygiene (Lecture 4)

ECE 4353
Chemical Process Safety
Government Responsibility &

Industrial Hygiene
(Lecture 4)
LEARNING OBJECTIVES
 Explain the government-industry’s responsibility for

health and safety
 Evaluate the nature of hazards posed by materials
which are flammable, toxic and reactive
 Identify and quantify common industrial methods to
control hazards.
Last Updated:6 October 2015 © LMS SEGi education group 2

Lecture 4
1.Government Responsibility for Health and

Safety
2. Industrial Hygiene
3. Threshold Limit Values

OSH ACTS IN MALAYSIA
FMA 1967 [ A c t 139] OSHA 1994 [ A c t

An514]
Act to to make further provisions for
An Act to provide for the control of
securing the safety, health and welfare of
factories with respect to matters
persons at work, for protecting others
relating to the safety, health and
against risks to safety or health in
welfare of persons, the registration
connection with the activities of persons
and inspection of machinery
at work.
(PRESCRIPTIVE) (SELF REGULATION)
Scope : Manufacturing,
quarrying, construction mining, OSH Scope : Manufacturing, quarrying,
ACT mining, construction, transport, finance,
public services, hotels, restaurants
PSMA 1984 [ A c t 302]

An Act to consolidate laws relating to safety in the transportation, storage
and utilization of petroleum and to provide for matters relating thereto.
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44
OSHA 1994

55
OSHA 1994
PHILOSOPHY OF OSHA
“ Responsibilities to ensure safety and
health at the workplace lies with those who
create the risk and with those who work with
the risk.”
• Self-regulation
• Consultation
• Workers cooperation and participation
66
OSHA 1994
OSHA requires employers to provide:

 Safe machine, equipment, tools and substances
 Safe place and environment to work
 Information, instruction, training and
supervision
 Safety & Health Policy
 Safety & Health Committee
 Notification of Accidents & Dangerous
Occurrence

77
OSHA 1994
OSHA requires employees to:

 to take care for the safety of yourself and other
persons.
 to cooperate with the employer or any other
person in the in charge of any duty, under the

act or regulations.
 to wear or use any protective equipment and
clothing.

88
WHAT’s NEXT…
After nearly 20 years of the OSHA enacted, DOSH

believes amendment should be made to this Act in order
to improve the procedure / existing ways of working in
line with current needs.
DOSH IS IN THE PROCESS TO COMBINE /

MIGRATE OSHA 1994 AND FMA TO
BECOME A NEW ACT.
The new Act will apply the concept of OSHA 1994 which
promotes SELF REGULATION; and maintain a few
requirements of FMA 1967 eg. Control of factories and
dangerous machinery eg. boilers
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99
© LMS SEGi education group
WHAT’s NEXT…
OSH SELF REGULATION PREVENTIVE

OWNERSHIP DOSH 2011 - 2015 CULTURE
DOSH 2005 - 2010 DOSH 2016 –
2020
LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

The way forward…
PREVENTIVE SAFETY
AND
HEALTH CULTURE
Government, employers and workers

actively p a rticipate in securing a safe
and healthy working environment.
4.2 Industrial Hygiene
<video on Industrial hygiene>

What is Industrial Hygiene?
Industrial Hygiene
Identification, evaluation and control of
occupational conditions that cause sickness
or injury.

Industrial Hygiene
 Identify hazards at workplace
 Evaluate magnitude of exposure
 Use control methods to reduce
exposures to acceptable levels

Industrial Hygiene – Identification
• Requires a thorough of chemical process, operating
conditions and operating procedures
• Sources of information
- Process design descriptions
- Operating instructions
- Safety reviews
- Safety datasheets

Industrial Hygiene - Safety Data Sheet (SDS)
• Safety Data Sheet (SDS), previously known as
MSDS, provides information on the properties of
hazardous chemicals and how they affect
health and safety in the workplace.
 the identity of the chemical,
 health and physicochemical hazards,
 safe handling and storage procedures,
 emergency procedures, and
 disposal considerations.

Industrial Hygiene - GHS
Globally Harmonized System (GHS)
 Global harmonization of chemical hazard

communication : classifications, labels, and
SDSs
 necessary to protect of human health and the
environment during the use and transport of
chemicals.
 Prevent confusion

Industrial Hygiene – Evaluation
• Aims to determine the extent and degree of exposure
to physical and chemical hazards
• Physical hazards
-Evaluated by comparing existing strength with threshold
values
• Chemical hazards
-Evaluated by comparing concentration of toxicants with

allowable limits
Industrial Hygiene – Evaluation
• Physical hazards – radiation, mechanical hazards,
noise, pressure, temperature
• Chemical hazards – liquids, dust, gas, fumes

Hazards of Pressure

Hazards of Pressure

Industrial Hygiene – Control
• Employ methods to eliminate or reduce exposure
resulting in elimination or reduction of the occurrence
of occupational disease through
 Engineering / Process interventions
 Administrative measures
 Personal protective equipment




Video on role of industrial hygienist

4.3 Threshold Limit Values (TLVs)
TLVs represent conditions to which all

workers
will be repeatedly exposed to everyday without
•adverse
For anyhealth
dose effects.
value below this dose, body is able
to detoxify.
• Agencies that establish TLVs
 The American Conference of Governmental
Hygienists (ACGIH)
 OSHA – they define permissible exposure levels
(PELs)
Threshold Limit Values
Time weighted average (TLV-TWA)

 average exposure on the basis of a 8h/day,
40h/week work schedule
 It is the maximum amount one may be exposed
to without adverse health effects over said
period.
 Once the TWA has been exceeded, the worker
may not re-enter the space for the remainder of
the day.
 TWA is expressed in ppm or mg/m3.
Short-term exposure limit (TLV-STEL)

 Maximum concentration to which workers can be
exposed for a period of up to 15 minutes
continuously without suffering intolerable
irritation or chronic/irreversible tissue damage.
 spot exposure for a duration of 15 minutes, that
cannot be repeated more than 4 times per day
with at least 60 minutes between exposure
periods
 If the predetermined limit has been exceeded, the
worker must remove him- or herself from the
hazard for at least one hour.
Ceiling limit (TLV-C)
• absolute exposure limit that should not be

exceeded at any time
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Immediately Dangerous to Life and Health

(IDLH)
condition when exposure is likely to cause death or

permanent adverse health effects

Permissible Exposure Limits
• Permissible exposure limit (PEL) is a regulatory limit

on the amount or concentration of a chemical that a
worker may be exposed to under OSHA regulations.
This is usually based on an eight-hour time weighted
average (TWA), although some are based on short-
term exposure limits (STEL).


Example :
CARBON MONOXIDE
NIOSH REL: 35 ppm TWA, 200 ppm CEILING

Current OSHA PEL: 50 ppm TWA
1989 OSHA PEL: 35 ppm TWA, 200 ppm CEILING
1993-1994 TLV: 25 ppm (29 mg/m3) TWA
Immediately Dangerous to Life or Health
Concentrations (IDLH): 1200 ppm

Toulene
Time Weighted Average (TWA) 10 ppm
TLV ceiling 500 ppm
Short Term Exposure Limit 50 ppm
(STEL)
Benzene
OSHA PEL 1.0 ppm
OSHA STEL 5 ppm
NIOSH REL (recommended exposure limit) 0.1 ppm
IDLH 500 ppm is shown;

Time Weighted Averages - Calculations
TIME WEIGHTED AVERAGES

Time Weighted Averages
CONTINUOUS MONITORING
OF CONCENTRATION OF TOXICANT IN AIR
C (t) = concentration of chemical ( ppm or mg/m3 )

t w = worker shift time (hours)
TWA is the average exposure to any hazardous contaminant in the

workplace on the basis of an 8 hour per day
The integral is always divided by 8 hours, independent of the length
of time actually worked in the shift.
The computation is normalized to 8 hours.
INTERMITTENT MONITORING
OF CONCENTRATION OF TOXICANT IN AIR
TWA = C1T1 + C2T2 + C3T3 +...

+CnTn
8 hrs







Permissible Exposure Limit


8 hour TWA Calculation

Example 1:
A worker works an 8 hour shift and is exposed to a
substance during that period at a level of 50
mg/m3.
TWA = (8x50)/8 = 50 mg/m3
Example 2:
A worker works an 8 hour shift, and is exposed to
toxic material for an hour at 200ppm.
TWA = 200 ppm / 8 hrs = 25 ppm

Example 1:
A worker works an 8 hour shift and is exposed to a
substance during that period at a level of 50
mg/m3.
TWA = (8x50)/8 = 50 mg/m3
Example 2:
A worker works an 8 hour shift, and is exposed to
toxic material for an hour at 200ppm.
TWA = 200 ppm / 8 hrs = 25 ppm

Example 3:
An employee works an 8 hour shift, and is exposed
to a substance for 3 hours at 0.15 mg/m3 and for
2 hours as 0.20 mg/m3.
TWA = ((3x0.15)+(2x0.2))/8 = 0.11 mg/m3
Working sessions may be broken down

as different processes may expose the
employee to the substance at different
levels, and breaks may stop exposure.
8 hour TWA Calculation – Longer exposure

Example 4:
An employee is working a 10 hour shift and
exposed to 6mg/m3 while at work.
TWA = (10x6)/8 = 7.5 mg/m3
Example 5:
A worker spends 10 hours exposed to 100 ppm.
TWA = (10/8)*100 = 125 ppm

8 hour TWA Calculation-shorter exposure

Example 6:
TLV-TWA of a substance is 10 ppm while TLV-STEL is
12ppm.
A worker is exposed to this substance for:
4 hrs @11 ppm, 2 hrs @14 ppm and 2 hrs @0 ppm.
TWA = 4 hr *11ppm + 2 hr*14 + 2*0
4hr + 2 hr + 2hr
8 hr TWA = 9 ppm
If an employee is working a 6 hour shift, they can be
exposed to higher levels within those 6 hours, than
they would be if they were working the full 8 hours.
For shorter exposure, you can adjust

the workplace exposure limit,
providing this
does not exceed any other exposure limit
eg. short term (15 minute) exposure
limit.
However, if you are going to expose an employee to an

exposure level above TLV-STEL, this exposure cannot
be repeated more than 4 times per day with at least 60
minutes between exposure periods

Evaluating Exposure to Vapors / Volatile
Toxicants
Example 7
The TLV-TWA for a substance is 150 ppm. A worker begins a work shift at 8am and
completes the shift at 5pm. A one-hour lunch break is included between 12 noon and
1pm. Assume that no exposure to the chemical occurs.
The following data was taken in the work area at the times indicated.
Has the worker exceeded the TLV?
Time Concentration (ppm)
8.10 am 110
9.05 am 130
10.07am 143
11.20 am 162
12.12 pm 142
1.17 pm 157
2.03 pm 159
3.13 pm 165
4.01 pm 153
5.00 pm 130
Evaluating Exposure to Vapors / Volatile
Toxicants
Start time ppm Exposed Exposed
Mins Hours C CC tt
8.00 110
8.10 110 10 0.17 110 18.7
9.05 130 55 0.92 120 110.4
10.07 143 62 1.03 136.5 140.6
11.20 162 73 1.22 152.5 186.0
12.00 146.6 40 0.67 154 103.2
12.12 142 12 0.20 0 0
1.00 153.1 48 0.80 0 0
1.17 157 17 0.28 155 43.4
2.03 159 46 0.77 158 121.7
3.13 165 70 1.17 162 189.5
4.01 153 48 0.80 159 127.2
5.00 130 59 0.98 141.5 138.7
Interpolated values TWA = 147.4 (<TLV)

Exposure limits for mixtures- Calculations
EXPOSURE LIMITS FOR

MIXTURES

C i
(TLV-TWA)mix =
C i
C i = concentration of chemicals

If the sum of concentration of mixture is more than (TLV-

TWA)mix
C i
C i
> C i
Sum of
concentrations of
toxicants in mixture
then workers are overexposed

If
C
>
i
then workers are overexposed 1




Example:
Air contains 5 ppm of diethylamine (TLV-TWA of
5ppm), 20ppm of cyclohexanol (TLV-TWA of
50ppm), and 10 ppm of propylene oxide (TLV-TWA
of 2ppm). What is the mixture TLV-TWA and has
this level been exceeded?

(TLV-TWA) mix = 5 + 20 + 10
5 + 20 + 10
5
50 2
= 5.5 ppm
C i = 5 + 20 + 10 = 35ppm
 Workers are overexposed

C i = 5 + 20 + 10
5 50 2
= 6.4 (>1)
TLV-TWA has been exceeded, workers

are overexposed.

Exposure limits > 8 hr work shifts

Exposure limits > 8 hr work shifts

Evaluating worker exposure to Dust
Determine the TLV for a uniform mixture of dusts

containing the following:
Dust A – 70 wt%, TLV = 20 mppcf (million particles per
cubic feet)
Dust B – 30 wt%, TLV = 2.7

Evaluating worker exposure to Dust
Determine the TLV for a uniform mixture of dusts containing the following:
Dust A – 70 wt%, TLV = 20 mppcf (million particles per cubic feet)
Dust B – 30 wt%, TLV = 2.7
TLV mixture = 1
C1 +
C2
TLV1
TLV2
0.70 0.30
= 2.7 1
+ 20
 Special control
= 6.8measures
mppcf is needed when particle count
> 6.8 mppcf.

Evaluating worker exposure to Noise

Evaluating worker exposure to Noise
Determine whether the following noise level is permissible with no additional
control features:
Noise level 85 dBA for duration of 3.6 hrs, 95 dBA for duration of 3.0 hrs and
110 dBA for 0.5hr.
C i = 3.6/16 + 3/4 + 0.5/0.5
= 1.97 (>1)
 Employees are overexposed to noise

Immediately wear ear protection. On long term, to
use noise reduction / control methods.






I Chose To Look The Other Way by Don
Merell
I could have saved a life that day,
But I chose to look the other
way.
It wasn’t that I didn’t care;
I had the time, and I was there.
But I didn’t want to seem a

fool, Or argue over a safety
rule.
I knew he’d done the job
before; If I spoke up he might
get sore.
The chances didn’t seem that

bad; I’d done the same, he knew
I had.
He took the chance, I closed an
eye; And with that act, I let him
die.
I could have saved a life that day,
But I chose to look the other
way.
Now every time I see his wife,

I know I should have saved his life.
That guilt is something I must bear;
But it isn’t something you need
share.
If you see a risk that others take

That puts their health or life at stake,
The question asked or thing you
say; Could help them live another
day.

Chemical Process Safety: Government Responsibility & Industrial Hygiene (Lecture 4)

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ECE 4353

Chemical Process Safety

Government Responsibility &

 Explain the government-industry’s responsibility for

Last Updated:6 October 2015 © LMS SEGi education group 2

1.Government Responsibility for Health and

3. Threshold Limit Values

Last Updated:6 October 2015 © LMS SEGi education group 3

FMA 1967 [ A c t 139] OSHA 1994 [ A c t

PSMA 1984 [ A c t 302]

LLaasstt UpdUpdaatetedd::66 OOcctotobbeerr 22001155 © LMS SEGi education group

OSHA requires employers to provide:

 Safe place and environment to work

 Information, instruction, training and

 Safety & Health Committee

 Notification of Accidents & Dangerous

LLaasstt UpdUpdaatetedd::66 OOcctotobbeerr 22001155 © LMS SEGi education group

OSHA requires employees to:

person in the in charge of any duty, under the

LLaasstt UpdUpdaatetedd::66 OOcctotobbeerr 22001155 © LMS SEGi education group

After nearly 20 years of the OSHA enacted, DOSH

DOSH IS IN THE PROCESS TO COMBINE /

OSH SELF REGULATION PREVENTIVE

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

Government, employers and workers

<video on Industrial hygiene>

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

 Evaluate magnitude of exposure

 Use control methods to reduce

exposures to acceptable levels

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

 Global harmonization of chemical hazard

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

-Evaluated by comparing concentration of toxicants with

• Chemical hazards – liquids, dust, gas, fumes

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

Last Updated:6 October 2015 © LMS SEGi education group 21

Last Updated:6 October 2015 © LMS SEGi education group 22

 Engineering / Process interventions

 Personal protective equipment

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

TLVs represent conditions to which all

 The American Conference of Governmental

Time weighted average (TLV-TWA)

Short-term exposure limit (TLV-STEL)

Ceiling limit (TLV-C)

• absolute exposure limit that should not be

Laasstt UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

Immediately Dangerous to Life and Health

condition when exposure is likely to cause death or

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

• Permissible exposure limit (PEL) is a regulatory limit

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

NIOSH REL: 35 ppm TWA, 200 ppm CEILING

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group

LLaasst UpdUpdaatetedd::66 OOcctotobbeer 22001155 © LMS SEGi education group