Safety Regulations And Training Manual

Transcription

Safety Regulations
And
Training Manual
Revised April 2009
Table of Contents
HILL PHOENIX SAFETY REGULATIONS AND TRAINING PROCEDURES............................................ 2
ACCIDENT AND INJURY RECORDING AND REPORTING ........................................................................ 3
EMERGENCIES: ACCIDENTS AND INJURIES .............................................................................................. 4
EMERGENCY ACTION AND FIRE PREVENTION PLAN ............................................................................. 5
FIRE EXTINGUISHER PLAN ............................................................................................................................ 10
HAZARD COMMUNICATION PROGRAM ..................................................................................................... 12
BLOODBOREN PATHOGENS ........................................................................................................................... 17
LOCKOUT/TAG-OUT GUIDELINES ................................................................................................................ 18
COMPRESSED GASES AND FLAMMABLE LIQUIDS ................................................................................. 21
LEAK TESTING .................................................................................................................................................... 23
PERSONAL PROTECTIVE EQUIPMENT ....................................................................................................... 24
HEARING CONSERVATION PROGRAM ....................................................................................................... 28
RESPIRATORY PROTECTION PROGRAM ................................................................................................... 32
MANUFACTURING OPERATIONS .................................................................................................................. 36
GRINDING SAFETY ............................................................................................................................................ 39
SPRAY FINISHING OPERATIONS ................................................................................................................... 40
TRAINING.............................................................................................................................................................. 41
FIRE EXTINGUISHER ..............................................................................................................................42
HAZCOM .....................................................................................................................................................52
BLOODBORNE PATHOGENS ................................................................................................................56
LOCKOUT/TAG-OUT ...............................................................................................................................68
COMPRESSED GAS TRAINING .............................................................................................................74
RESPIRATORY PROTECTION TRAINING .........................................................................................79
PPE ...............................................................................................................................................................89
MACHINE GUARDING ............................................................................................................................95
FALLS ..........................................................................................................................................................98
ELECTRICAL SAFETY ..........................................................................................................................102
LADDER SAFETY ....................................................................................................................................107
HEARING CONSERVATION TRAINING ............................................................................................109
WORKPLACE VIOLENCE.....................................................................................................................112
FORKLIFT SAFETY TRAINING...........................................................................................................113
| Hill PHOENIX Safety Regulations and Training Procedures 1
Hill PHOENIX Safety Regulations and Training Procedures
Hill PHOENIX has established comprehensive safety policies and procedures that comply with the Occupational
Safety and Health Administration’s (OSHA) regulations and training requirements.
Safety in all aspects of our work is top priority at Hill PHOENIX. To ensure that all employees in our organization
know the safe way to do their jobs and meet OSHA’s safety regulations, we have established a Safety Training
Program. This manual spells out the training provided to make this a safe place in which to work and your
responsibilities in following these safety policies.
Benefits of Safety Training
1. Protect employees from physical injury and other health hazards and improve overall health of employees;
2. Increase productivity; safe work practices reduce accidents and keeps productivity up;
3. Lower workers’ compensation costs;
4. Improve employee morale by making employees confident about working in a safe environment;
5. Promote safety awareness by emphasizing safety and health through training and employees respond by thinking
about safety;
6. Avoid disasters; and
7. Comply with OSHA regulations.
As an employee, you have three major responsibilities:
1. To follow both general safety practices and specific safety procedures of your job;
2. To encourage your co-workers to follow safe work practices; and
3. To think and use good sense judgment in areas not addressed by written policies.
| Hill PHOENIX Safety Regulations and Training Procedures 2
Accident and Injury Recording and Reporting
Policy: Through timely and complete investigation of all accidents and injuries, Hill PHOENIX intends to obtain all
information required to prevent the occurrence of accidents, injuries and property damage.
Procedure
A.
Accident Investigation and Reporting
1. All injuries must be reported within 24 hours on a Hill PHOENIX Accident Investigation Report.
2. Minor injuries will be investigated immediately by the manager or supervisor and reported promptly, no later
than the end of the shift in which the accident occurred.
3. Accidents involving serious injury such as fractures, severe lacerations, amputation, unconsciousness, etc.,
will be reported immediately to the department manager, Human Resources Director, and Plant Operations
Director. The team leader, supervisor, or department manager will conduct a complete “on-the-scene”
investigation of the accident and complete a Hill PHOENIX Accident Investigation Report.
4. The accident report must include the nature of the injury and any hazardous condition surrounding the
accident or unsafe act that may have caused or permitted the accident to occur.
For serious injuries, written statements will be taken from all eyewitnesses.
B.
Records
1. The team leader, supervisor, or department manager are to submit copies of Accident Investigation Report to
the Human Resources Department.
2. The Human Resources Department will maintain a comprehensive annual summary report (OSHA 300) of
illnesses and injuries. An OSHA 300A will be posted in the Employee Break Room February 1 through
April 30, per OSHA requirements.
Note: All accidents must be reported to the Human Resources Department on the Accident Investigation Report and
Work-Related Injury Report – Employee regardless of how minor.
| Accident and Injury Recording and Reporting 3
Emergencies: Accidents and Injuries
Accident Policy
Each employee is responsible to report every work-related injury to his/her team leader, manager or supervisor.
Failure to report work-related injuries may cause the employee to lose workers’ compensation coverage to which
he/she might otherwise be entitled. Each team leader, manager or supervisor is responsible for completing the
Accident Investigation Report and for seeing that his/her employees fill out a Work-Related Injury Report –
Employee. In addition, the team leader, manager or supervisor is responsible for seeing that all injuries and
accidents are reported to Human Resources and all injuries receive immediate treatment regardless of how minor.
First-Aid Injuries
Minor injuries such as cuts, scratches, bruises, and burns that do not require a doctor’s treatment should be treated
using supplies from a first aid station or kit.
Minor Injuries
Employees with an injury requiring the treatment of a physician may be transported to a facility by himself/herself if
the employee is able to drive. If the employee is unable to drive, the employee may be transported by another
employee approved by Human Resources to transport.
Any employee involved in an “on-the-job” accident will be required to undergo a drug screen.
Serious Injuries
In the case of a serious accident requiring the attention of paramedics or emergency transport, dial 911 for the nearest
emergency medical center.
*A team leader, manager or supervisor should immediately notify Human Resources.
Eye Washes
If the eyes or body of any person is exposed to corrosive materials, immediately flush the eyes at an eyewash station.
Team leader, manager or supervisor are responsible for showing employees the location for the emergency eye wash
equipment. Employees will be trained during their first day orientation and shown the location of the eyewash
station.
| Emergencies: Accidents and Injuries 4
Emergency Action and Fire Prevention Plan
I.
Introduction
A.
This emergency action and fire prevention plan applies to Hill Phoenix . The purpose of this plan is
to provide employees with facility specific information and instructions that will allow them to take
appropriate action should an emergency arise in the workplace.
B.
Workplace emergencies include fire, chemical releases, weather-related concerns, medical
emergencies and security-related issues such as a bomb threat. This plan provides employees with the
preferred means for reporting and responding to these types of emergencies.
C.
This written plan has been prepared to meet the requirements of the Occupational Safety and Health
Administration (OSHA) employee emergency and fire prevention plans, OSHA 29CFR 1910.38.
According to this regulation, the plan must be maintained in the facility and made available for
employee review. As such, this plan will be maintained in the HR department and each department. It
will be made available for employee review upon request.
II.
Emergency Resources and Responsibilities
This company is committed to provide a workplace for its employees that comply with OSHA’s
health and safety requirements. Being prepared for emergencies that may affect Hill PHOENIX
employees is part of that commitment. To ensure facility preparedness in case of an emergency, the
following resources will be made available to assist before, during and after an emergency.
III.
Emergency Response Organization
This company has established an organization of personnel to respond to emergencies and to
facilitate evacuations.
Primary Emergency Numbers
For Primary Emergency Numbers, see each location’s specific Emergency Action and Fire
Prevention Plan.
IV.
Emergency Coordinators
For Emergency Coordinators, see each location’s specific Emergency Action and Fire Prevention
Plan.
A.
The Emergency Coordinator is responsible for:
i.
Coordination emergency response procedures with local response organizations (e.g., police,
fire, rescue, local medical facility, etc.).
| Emergency Action and Fire Prevention Plan 5
V.
ii.
Greeting emergency responders upon their arrival to the facility, providing them with
specific information regarding the emergency and informing them of the results of the
evacuation head count.
iii.
Initiating incidental spill response within the facility.
iv.
Ensuring that an adequate number of employees are trained on how to properly use fire
extinguishers and how to respond to a chemical spill.
v.
Inspecting the facilities emergency response equipment (e.g., fire extinguishers, first aid kits,
spill response kits, etc.) on a monthly basis.
vi.
Critiquing emergency responses to ensure that the provisions of this plan are satisfactory.
vii.
Conducting initial damage assessments after an incident has occurred.
viii.
Communicating decisions and action plans in the event of an emergency to employees.
ix.
Informing and updating company management on the status of the emergency.
x.
Training or setting up training for all employees and new hires on the emergency procedures
in this plan.
Evacuation Coordinators
To assist with evacuation procedures, evacuation coordinators have been appointed.
VI.
VII.
Evacuation Coordinators are responsible for:
A.
Maintaining a current employee roster in their area of responsibility.
B.
Notifying the emergency coordinator when they will be out of the facility.
C.
Assisting employees during evacuation and ensuring that their area of responsibility has been totally
evacuated.
D.
Conducting a head count in the assembly area and reporting results of head count to the emergency
coordinator.
Employees
A.
All employees are responsible for the following:
i.
Reporting all emergencies to their supervisor.
ii.
Knowing the emergency procedures present in this plan.
iii.
Following the instructions of the Evacuation and Emergency coordinators and local or state
emergency responders.
iv.
Knowing the nearest exit and evacuation route from their work area.
VIII.
v.
Knowing the location of the fire extinguishers.
vi.
Informing the receptionist when you are expecting visitors and ensure all visitors sign the
guest log.
vii.
Employees must report any blocked exit immediately.
Emergency Response Equipment/Supplies
The following emergency response equipment is available for employees use:
A.
I.
II.
III.
IX.
B.
Fire Extinguishers are located at strategic points throughout the facility. All are type ABC fire
extinguishers. Fire extinguishers are intended for use on small, manageable fires only and by trained
employees in the initial stages only (beginning stage). The health and safety of employees must
not be put at risk.
C.
Emergency First Aid Kit is located in each plant.
Note: This kit is equipped with first aid supplies only.
D.
Location of other equipment
Personal protective equipment, such as gloves, and safety glasses are available from the tool crib.
Emergency Exits
Each exit or way access to an exit shall:
I.
Remain unlocked from the inside and unobstructed at all times.
II.
Be clearly marked by a sign reading EXIT.
A.
X.
Type ABC Fire Extinguishers
Eye Wash Stations
Personal Protection Equipment
Emergency Procedures
Unless otherwise instructed, the following procedures will be implemented. Only employees that are certified
will be permitted to provide emergency medical services within this facility.
A.
Medical Illness or Physical Injury
I.
In the event of a serious life threatening medical incident or a physical injury call for an ambulance
by dialing 911.
II.
Give a complete description of the facility location and the nature of the injury to the dispatcher (i.e.
Hill PHOENIX 709 Sigman Rd. Conyers). Give the dispatcher the office phone number (i.e. 770285-3100). Do not hang up until you have answered all the dispatcher’s questions and they have
ended the call.
III.
Instruct an employee to go to the parking lot to meet the Emergency Medical Service (EMS) and
direct the paramedics to the location of injured party.
IV.
Do not attempt to move an injured person unless he/she is in immediate danger. Do not leave an
injured or trapped person alone unless doing so put you at risk of injury.
V.
Make the person as comfortable as possible until trained medical personal arrive. Do not initiate first
aid unless you are trained to do so.
VI.
If the injury is not serious but will require immediate medical attention, transport employee to the
nearest hospital.
VII.
For all cases requiring immediate medical attention, an employee will accompany the injured
employee to the doctor/hospital. Once at the doctor/hospital, he/she should remain with the injured
employee to contact the family and provide information of employee’s status to the company, and
transport the employee back after being treated and released, if necessary.
VIII. All work related injuries and illnesses must be reported to the employee’s supervisor immediately
after their occurrence. Each supervisor must notify Human Resources of all work-related
injury/illness within 24 hours.
XI.
Classification of Fires
The first minutes of a fire largely determine the amount of damage it will do. In a brief time, a fire can
multiply greatly. Portable Extinguishers may mean the difference between a minor accident and a major
disaster. The right extinguisher in the right place can make short work of a fire or have it under control when
the fire department arrives. Fires are referred to as Class A, Class B, and Class C. (See Fire Extinguisher
Plan)
XII.
Fire Prevention Plan
The procedure to be maintained for the Fire Prevention Plan:
XIII.
A.
Extinguisher fire only if you have been trained and the fire is in the initial stages.
B.
Evacuate the building immediately, in an orderly fashion, report to assigned area, as listed in the
Emergency Evacuation Plan.
C.
Do not enter building until instructed to do so.
D.
Housekeeping plays a vital role in the prevention of fires, and management is committed to
maintaining “Housekeeping” procedures.
Weather Related Emergencies
In case of a weather-related emergency, the Human Resources Director will communicate, via the public
address system, whether or not early dismissal or evacuation is necessary.
XIV.
Security Issues
A.
Employees must notify their supervisor immediately if they receive a threatening telephone call or
message (internal or external). If an employee is being threatened, report events to their supervisor.
B.
C.
If possible, the following procedures should be implemented if a threatening telephone call is
received.
I.
Identify caller and the time threat was received.
II.
Ask the following questions:
A. Who or what is the target of the threat?
B. When will the threat be carried out?
C. Why is the threat being made?
D. If a bomb threat, where is the bomb, what does it look like, what kind of bomb, when is
it set to go off?
Fire Inspection Report
Facilities maintenance personnel will conducts an inspection monthly and a summary report is
submitted to staff personnel.
D.
Fire Extinguisher Inspection Report
Facilities maintenance personnel will conducts an inspection monthly and a summary report is
submitted to staff personnel.
XV.
Emergency Evacuation
In accordance with OSHA 1910.38 - Employee Emergency Plan, Hill PHOENIX has established guidelines
for each location.
Fire Extinguishing Plan
I. Purpose
This plan is to familiarize all employees with general principles of fire extinguishing usage and hazards involved with
fighting fires.
II. Scope
This program applies to the usage, placement, maintenance and testing of portable fire extinguishers.
III. Types of Fires and Extinguishers to be used
CLASS A Fire
A fire is classified as a Class A when the material burning is wood, paper, rags, weeds or similar materials.
Class A fire can be extinguished by a cooling source. Water is the first choice when combating Class A fires.
If water or water filled extinguishers are not available, use dry chemical extinguishers.
CLASS B Fire
A fire is classified as a Class B when the material burning is oil, paint, gasoline, kerosene or other flammable
liquid. Class B fire is best extinguished by smothering. Dry chemical, foam, and carbon dioxide extinguishers
provide a smothering blanket over the burning surface of the liquid, preventing oxygen from reaching the
surface and extinguishing the fire. Water should not be used as it will spread the burning liquid in a Class B
fire.
CLASS C Fire
A fire is classified as a Class C when it is of the electrical origin. Class C fires can be extinguished by first
breaking the circuit (if possible). Use dry chemical or carbon dioxide portable extinguishers on Class C fires.
DO NOT use water.
At Hill PHOENIX, multi-purpose ABC fire extinguishers are good for all types of fires.
IV. Placement
1. Fire extinguishers shall be mounted, identified and located so that they are readily accessible to employees
without subjecting them to possible injury.
2. Only approved fire extinguishers shall be used.
3. Portable fire extinguishers shall be maintained in a fully-charged and operable condition and kept in their
designated places at all times (see Section V.)
4. Fire extinguishers for use with Class A fires should be located so that the travel distance for employees to any
extinguisher is 75 feet or less.
5. Fire extinguishers for use with Class B fires should be located so that the travel distance for employees to any
extinguisher is 50 feet or less.
| Fire Extinguishing Plan 10
6. Fire extinguishers for use with Class C hazards should be located based on the appropriate pattern for existing
Class A or B fires.
7. Facilities Maintenance is responsible to assure compliance with all requirements of this plan.
V. Inspection and Maintenance
1.
Portable extinguishers shall be visually inspected monthly. The monthly inspection shall include the
following visual checks:
a)
b)
c)
d)
Check pressure gauge; the needle should be in the green area. If the needle is in the red recharge or
overcharged areas, immediately remove from service and have it repaired.
Make sure pin is in place.
Initial and date the monthly inspection record on the tag of each fire extinguisher.
The monthly fire extinguisher visual checks shall be performed by managers and/or supervisors
under the supervision of the Facilities Maintenance.
2.
Portable fire extinguishers shall be subjected to annual maintenance checks. Stored pressure extinguishers
do not require an internal examination. The inspector shall record the annual maintenance date and retain the
record for one year after the last entry. The annual maintenance checks shall be performed by outside
contractors under the direction of the Facilities Maintenance. The contractor shall attach a tag serving as the
record of inspection for each fire extinguisher.
3.
Alternate equivalent protection shall be provided when portable fire extinguishers are removed for service or
maintenance and recharging.
VII. Use of Extinguishers
Only trained personnel should use the fire extinguishers.
VIII.
Employee Training
Training shall conform to OSHA standard 1910.157(g)(1), (2), and (4)
1. Employees will become familiarized with the general principles of fire extinguisher usage and hazards involved
with fire fighting during annual training.
2. Employees who have been designated to use fire-fighting equipment as part of the Emergency Action and Fire
Prevention Plan shall be provided with training in use of appropriate equipment.
3. Training shall be done annually by or under the direction of the Human Resources Department.
4. A copy of the “Fire Extinguisher Plan Training” form is listed.
| Fire Extinguishing Plan 11
Hazard Communication Program
The Company maintains a Hazard Communication Program consistent with OSHA regulations. The purpose of this
program is to ensure that every employee is aware of hazardous materials in his/her workplace and receives proper
training in safe handling and the usage of those materials. The Hazard Communication Program is divided into four
(4) parts:
1.
2.
3.
4.
I.
Container Labeling
Material Safety and Data Sheets (MSDS)
Contractor Hazard Communication
Hazard Communication Employee Training
Container Labeling
The main purpose of a label is to provide the identity of the hazardous materials, a warning of the hazards, and who
to contact for further information. The chemical name(s) appearing on the label should be identical to the chemical
name(s) appearing on the corresponding MSDS.
Initially, suppliers are responsible for proper labeling of containers; however, our policy is to check containers before
use to ensure proper labeling. Containers arriving from the chemical manufacturers and/or distributors shall be
inspected by receiving personnel and containers of hazardous substances must not be used until the below label
information is verified:
a)
b)
c)
d)
e)
II.
Labels on incoming shipments of hazardous chemicals have not been removed or defaced.
Labels and warnings are legible, in English, and prominently displayed on the container.
Hazardous materials are identified.
Hazardous warnings are listed.
The name and address of the manufacturer are supplied.
Material Safety Data Sheets
MSDS for all hazardous substances shall be maintained on file and kept at each location
MSDS may also be kept in a Safety Database or by using the Internet as long as all employee have access to the
sheets.
Procedure
1. Managers and Supervisors are responsible for making sure that the hazardous substances in each department
have the related MSDS on file. As an employee, you are responsible for reading the MSDSs on file.
2. MSDS Sheets must be organized according to their trade name and chemical composition.
Yearly MSDS Review
1. MSDSs for materials no longer used will be maintained for a period as designated by OSHA.
2. A yearly review of all chemicals and hazardous materials shall be conducted every December.
| Hazard Communication Program 12
MSDS are available for all chemicals in inventory. The MSDS describes, in detail, the features of a chemical
substance. It communicates information on hazards, precautions for handling, and emergency and first aid
procedures for each chemical present at Hill PHOENIX. Each MSDS typically contains the following general
information:
•
•
•
•
•
•
•
Manufacturer’s name, address and phone number
The date of the sheet’s preparation or revision
Product identification including chemical, common and trade names must be included on the label
CAS Number - the identification number assigned by the Chemical Abstracts Service to a particular
chemical substance.
Chemical formula
Chemical Family - indicates the general class of compounds in which the hazardous substance is a
member (acids, ketones, etc.).
Hazardous ingredients of mixture
If the hazardous chemical is a mixture, which has been tested as a whole to determine its hazards, the chemical and
common name(s) of the ingredients which contribute to these known hazards, and the common names(s) of the
mixture itself shall be listed.
If the hazardous chemical has not been tested as a whole, the chemical and common name(s) of all ingredients which
have been determined to be a hazard, and which comprise 1% or greater of the composition shall be listed (except the
chemicals identified as cancer-producing shall be listed if the concentration is 0.1% or greater). Also, if the
hazardous chemical has not been tested as a whole, the chemical and common name(s) of all ingredients which have
been determined to be health hazards and which comprise less than 1% (0.1% for carcinogens) of the mixture shall be
listed if there is evidence that an ingredient(s) could be released from the mixture in concentrations which would
exceed an established OSHA permissible exposure limit or ACGIH threshold limit value or could present a health
hazard to employees.
Finally, the same process applies when the chemical and common names of all ingredients have been determined to
present a physical hazard when present in the mixture.
•
•
•
•
•
Physical data including vapor pressure, flash point, specific gravity, boiling point, etc.
Fire and explosion data including; the primary route(s) of exposure, established potential carcinogen in the
International Agency for Research on Cancer (IARC).
Health hazard information including: the primary route(s) of exposure, established exposure limits (listed
as the permissible exposure limit or PEL, of the threshold limit value or TLV), potential adverse health
effects of exposure, signs and symptoms of exposure, and conditions aggravated by exposure, and the
chemical is listed in the National Toxicology Program (NTP) Annual Report on Carcinogens or has been
found to be a potential carcinogen in the International Agency for Research on Cancer (IARC
Monographs), or by OSHA.
Precautions for safety use and handling including appropriate hygienic practices, protective measures
during repair and maintenance of contaminated equipment, and procedures for clean up of leaks and
disposal of materials.
Control measures including engineering controls, work practices and personal protective equipment.
Emergency and First-Aid Procedures
Human Resources shall be responsible for obtaining MSDSs listed in the chemical inventory and for which a label
has been developed from chemical material suppliers and/or manufacturers. In addition, Materials shall be
responsible for making sure that incoming data is reviewed for new and significant health/safety information and that
such new information is added to the inventory and MSDSs. Evaluation of these MSDSs shall be based on current
OSHA, ACGIH, NIP, NIOSH, and accredited hazardous materials, books and manuals. If Human Resources
becomes informed of any new and significant health and safety information for a chemical due to such reviews, that
information will be distributed.
•
•
•
If a gross omission or error is found, a telephone call to the manufacturer will be made requesting the
necessary information. If no positive feedback is received within 2 weeks, Hill PHOENIX may discontinue
use of the product.
Copies of the MSDSs appropriate to each area will be kept together as listed in Section III. A complete set
of MSDSs will be kept by Human Resources in a notebook-type binder(s) along with the written program.
All MSDSs are available for review by employees during working hours. Requests for copies of MSDSs
will be honored within 72 hours of the request. The employee should contact Human Resources to assist in
identifying the chemical and finding its proper MSDS.
If a MSDS is not available or if a new chemical is in use that is not on the inventory and does not have a
MSDS, employees should immediately contact their team leader, manager, or supervisor. Human
Resources will determine if the chemical meets the definition of “hazardous chemical” and if it does,
he/she shall add the chemical to the inventory.
III.
Informing Contractors
Contractors who may be exposed to hazardous chemicals will by informed both verbally and by means of an
information sheet, as to hazards involved, at a meeting before any work is accomplished.
Hill PHOENIX will provide contractors with a copy of our Hazard Communication Program and instruction to
provide us a list of the hazardous chemicals they may use.
IV.
Employee Training
Training shall conform to OSHA standard 1910.1200(h)(1), (2)(i) through (iii), and (3)(i) through (iv)
“Right to Know” Law
1. As an employee, you are entitled to know of any hazardous substances in your work area. This includes
methods to detect the presence of a hazardous material, and the physical and health hazards of the chemicals
in your work area.
2. Hill PHOENIX will also provide training to employees on protecting themselves from these hazards through
appropriate work practices, emergency procedures, applicable personal protective equipment, and hazardous
material labeling.
Hazard Communicating Program
•
Labeling. All hazardous chemical containers should have labels identifying the specific chemical and the
physical and health hazard associated with that chemical. A hazardous communication label easily identifies
these labels: a colored diamond label, blue, red, yellow or white.
Color Diamond
Blue
Red
Yellow
White
Hazard
Health Hazard
Fire
Reactivity
Specific Hazard
A number inside the diamond will indicate the level of the hazard. One (1) is slightly hazardous and four (4)
is deadly.
Physical and Health Hazards of Chemicals
1. For all hazardous chemicals, the physical and health hazards for that chemical is listed on the corresponding
material safety data sheet.
2. The MSDS will also provide information on detecting the chemical and physical signs of exposure.
Protective Measures
1. As an employee, you must familiarize yourself with the hazardous chemicals in your work area. Find the MSDS
for these chemicals.
2. Once you have located the MSDS, read the recommended protective equipment and emergency procedures for
that chemical.
Training
All persons employed by Hill PHOENIX who may be exposed to chemicals in the workplace shall be trained
regarding the characteristics and safe handling of hazardous chemicals in the workplace at the time of initial
assignment and annually thereafter, prior to assignment on non-routine tasks and whenever a new hazard is
introduced into the workplace environment. The Human Resources will direct the training program and maintain a
record of employee attendance. Information covered in the training course shall include the following:
1.
Requirements of the OSHA Hazard Communication Standard
2.
The location and availability of Hill PHOENIX’s written Hazard Communication Plan including:
a)
An explanation of the labeling system.
b)
An explanation of the MSDS and how to obtain and use them to find the appropriate hazard
information.
c)
The location of hazardous chemicals to which each employee may be exposed.
d)
The name(s) of hazardous substances present in the work area including generic, chemical, common
and trade names.
e)
The physical and chemical properties of hazardous substances to which employees may be exposed.
f)
Definition of terms (e.g., exposure, TLV, PEL, etc.)
g)
Short and long-term health effects of exposure to hazardous materials.
h)
i)
j)
k)
Symptoms of exposure.
Methods and observations that may be used to detect the presence or release of hazardous chemicals
in the work area (such as monitoring conducted by the employer, continuous monitoring devices,
visual appearance or odor of hazardous materials then released.)
Safe handling of hazardous materials.
Emergency procedures to follow if exposed to hazardous materials.
i)
How to control exposure to hazardous chemicals through safe work practices and personal
protective equipment.
Non-Routine Tasks
In the event that an employee may be required to perform a non-routine task, such as entering confined spaces
(trench, excavation, tank) or breaking and opening piping systems and includes the use of chemicals, the employee
will be given information by their Department Manager about hazards involved with such activities. This
information shall include:
•
•
•
Specific chemical hazards.
Control measures the employee can take.
Measures Hill PHOENIX has taken to lessen the hazards (i.e., ventilation, respirators.)
Bloodborne Pathogens
Bloodborne Pathogens are pathogenic microorganisms that are present in human blood and can cause diseases in
humans. These pathogens include but are not limited to Hepatitis B (HBV), and Human Immunodeficiency Virus
(HIV). Bloodborne Pathogens can be devastating; just a few drops of infected blood or other fluids can contain
hundreds of thousands of infectious microorganisms.
Hill PHOENIX has the responsibility to ensure that employees do not come into contact with blood or other
potentially infectious material while performing their job. Hill PHOENIX shall provide hand-washing facilities,
which are readily accessible to employees. Universal Precautions-all human blood and bodily fluids are treated as if
known to be infectious for (HIV,HBV). Hand washing often is an effective way of limited exposure.
OSHA estimates that HBV annually accounts for approximately 7400 workplace-related deaths and bodily infections
from Bloodborne Pathogens. HBV is an inflammation of the liver that is transmitted by blood and other bodily
fluids. It can result in severe liver damage, cirrhosis of the liver and death. Fortunately, there is a vaccine available
that is 90 percent effective against HBV. There is no vaccine for the deadly virus HIV. It attacks the body’s immune
system and leads to acquired immune deficiency syndrome, AIDS. And AIDS is always fatal.
Hepatitis B Vaccination shall be available to all employees with risks of exposure. If an employee declines
vaccination but later decides to accept the vaccination, Hill PHOENIX shall make available hepatitis B vaccination at
that time. Employees who are offered by Hill PHOENIX the hepatitis B vaccination and decline to accept will need
to sign a waiver.
Remember it is your responsibility to make your workplace safe for yourself and other associates.
Exposure Control Plan
Hill PHOENIX shall maintain a separate Exposure Control Plan. Human Resources will be responsible for
maintaining the plan.
Employee Training
Training shall conform to OSHA standard 1910.1030(g)(2)(i); (ii)(A) through (C); (iii) through (vii)A through (N);
(viii) and (ix)(A) through (C)
Training will be provided to all employees with occupational exposure a the time of initial assignment to task where
occupational exposure may take place; with 90 days after the effective date of the standard; and at least annually
thereafter.
| Bloodborne Pathogens 17
Lockout/Tag-out Guidelines
I. Purpose and Scope
Failure to properly lock out and tag equipment before starting to work on it can expose employees to needless
hazards. Maintenance people, particularly, can be subjected to injury unless certain steps are taken to prevent
accidental or unauthorized operation of the equipment. Maintenance work follows no definite pattern, as each job
may be different from any other job. Each employee may work under a different supervisor and what constitutes safe
practices may vary in different sections of a department, operation, or facility.
Operations employees may also be required to lock and tag switches and valves in the course of their work during
cleaning and setting up of breaks, punches, vessels, or other equipment. It is essential that one basic safety policy,
requiring the use of safety locks and danger tags, be followed to eliminate conflicting practices and needless exposure
to danger. This guide establishes Hill PHOENIX’s requirements necessary for locking out and tagging machines and
equipment.
II. Lockout/Tag-out Procedures
1.
Safety locks and danger tags will be maintained and issued as required by the Maintenance Department to
any employee working on equipment, such as electrical gear, and lines containing flammable gasses or
liquids, hydraulic fluids, corrosives, acids, or other toxic materials. The safety locks and danger tags will be
used to lockout and tag equipment when making repairs, adjustments, lubricating, cleaning or doing any work
where there is danger of being injured should the equipment be started or put into operation while such work
is being done. This may require that both electrical switches and isolation valves be locked and tagged at the
same time. Danger tags and locks should be used together. Danger tags should never be used in place of a
lock.
a)
b)
c)
d)
All personnel will be required to check out Lockout/Tag-out equipment from the Maintenance
Department before working on equipment that falls into the Lockout/Tag-out guidelines.
The safety lock and danger tag will be placed on equipment controls before any work being done on
the equipment.
No one except the employee who placed the safety lock on the equipment shall remove it. The only
exception will be made when the person who placed the lock and tag is not on the plant property and
cannot be reached. However, in such cases, the Supervisor responsible for the work must personally
survey and evaluate the entire work area to determine if the lock and tag may be removed safely.
All other personnel who may be exposed to the possibility of injury should add their locks and tags.
2.
Automatic equipment has a built-in memory and in many instances may cycle or be activated in some manner
when power is restored in equipment.
a)
Operating supervision* of the department normally responsible for the equipment must take
responsibility for proper shutdown of the equipment where work is to be performed.
3.
After the main switch has been pulled and/or control valve closed, equipment must be tried to be sure it will
not operate. A safety lock must then be placed on the equipment to prevent power or utilities being put into
operation while the equipment is being worked on. Danger tags must accompany safety locks.
4.
All switches, valves or control points between the one locked out and the equipment must in “OFF” position
so that when power or utility is restored, no damage can be done by auxiliary control points being in an “ON”
position.
| Lockout/Tag-out Guidelines 18
5.
When locking out hydraulically and/or pneumatically activated equipment, these additional precautions must
be taken:
a)
b)
c)
Check the hydraulic unit to make certain that the pump is not operating. At the same time, make a
visual check of the pressure gauge.
Before breaking or opening any airlines, bleed the pressure from all lines and units.
Check the hydraulic system to see if it has an accumulator. If it does, open the discharge valve and
discharge the pressure back to the tank.
6.
After the necessary work has been completed, operating supervision* of the department responsible will be
notified and then the safety locks and danger tags can be removed.
7.
Lockout/Tag-out to be used during Production Operation:
a)
b)
c)
Pumping up Racks
i)
All pressure tanks should be secured on the floor
ii)
Bleed down pressure
Area Around Racks
i)
“High Voltage” sign posted
ii)
“Authorized Personnel” sign posted
Area around Houses
i)
“High Voltage” sign posted
ii)
“Authorized Personnel” sign posted
iii)
Every open panel needs to be secured and tagged
III. Areas to be supplied with Lockout/Tag-out Equipment
1. The Maintenance Department will be responsible for issuing the Lockout/Tag-out supplies as needed.
2.
3. The Quality Control Department will be issued their own lockout keys and tags.
IV. Employee Training
Training shall conform to OSHA standard 1910.147(a)(3)(ii); (4)(i)(D);(7)(i)(A) through (C); (ii)(A) through (F);
(iii)(A) through (C)(iv) and (8)
Training will be provided to ensure that the purpose and function of the Energy Control Program is understood by all
employees. New hires will be trained immediately during orientation.
NOTE: These rules are established for the protection of the employees involved and are subject to change at the
discretion of Management.
*Certification of the above training includes the employee’s names and the dates of training and includes an
adequate supply of durable Lockout/Tagout devices which have been standardized in at least one of the following
criteria:
• Color
• Shape
• Size
• Print and Format
IV.
Annual Review
Facilities Maintenance will be responsible to review the Energy Control Program annually.
Compressed Gases and Flammable Liquids
All compressed gases used at Hill PHOENIX including acetylene, hydrogen, oxygen, nitrogen and argon shall
comply with the Compressed Gas Association Pamphlets. This encompasses the handling, storage and use of these
materials, as well as the required training.
Procedure
Compressed Gases
1.
2.
3.
4.
5.
6.
7.
8.
Air receivers must have accessible drains, handholes and manholes.
A drainpipe and valve must be installed at the lowest point of every air receiver for oil and water removal.
Air receivers must be drained frequently.
All air receivers must be equipped with an indicating pressure gauge and a spring-loaded safety valve. No valve
of any type should be placed between the air receiver and its safety valve(s).
All compressed gas cylinders and portable tanks shall have pressure-relief devices.
All Safety Valves must be tested frequently at regular intervals to determine its operating condition.
For acetylene and propane, the location area must be clearly marked as follows: “PROPANE-FLAMMABLE
GAS - NO SMOKING - NO OPEN FLAMES” for each gas.
Team leaders, Managers and Supervisors are responsible for reading the MSDSs for all compressed gases used at
Hill PHOENIX.
Handling and Storage Requirements
Acetylene, Nitrogen, Oxygen, Argon and Propane
1.
For acetylene, use a pressure-reducing regulator set at less than 15 PSIG. For all other gases, use a pressurereducing regulator and pressure-relief devices when connecting to lower pressure-relief devices.
2.
Avoid exposing oxygen to flammable materials, especially petroleum products, asphalt and other volatile
flammables. A direct stream of oxygen must never come in contact with an petroleum-based product (oil,
gasoline, grease, etc.)
3.
Oxygen cylinders should not be stored within 20 feet of flammable or combustible materials, especially oil or
grease, or be separated by a non-combustible barrier at least 5 feet high having a fire resistance rating of at least
one-half hour. If oxygen and grease mix, they are explosive.
4.
Storage should not be in heavy traffic areas.
5.
Valve caps must remain on cylinders not connected for use.
6.
Keep acetylene cylinders storage areas away from storage of oxygen.
7.
Storage areas must be free of combustible material and well ventilated.
8.
Never expose cylinders to heat.
9.
Segregate full and empty cylinders.
10. Never roll, drag, or slide cylinders, even for a short distance. ALWAYS USE A SUITABLE HAND TRUCK.
| Compressed Gases and Flammable Liquids 21
11. Keep cylinders far enough from welding or cutting so that sparks, flames or slag will not reach them.
12. Cylinders stored outside must be protected from weather and direct sun rays.
Flammable and Combustible Liquids
Flammable liquids must be kept in covered containers or tanks when not actually in use. All employees must take
adequate precautions to prevent the ignition of flammable vapors. Sources of ignition include open flames, lighting,
smoking, cutting and welding, hot surfaces, friction heat, static, electrical and mechanical sparks, spontaneous
ignition, including heat-producing chemical reactions, and radiant heat.
| Compressed Gases and Flammable Liquids 22
Leak Testing
Leak testing involves pressurizing a refrigeration system to inspect for any type of leaks. Leak testing is a vital
element in the quality control process. A few leaks that go undetected can cost our Company the entire profit for that
job. Leaks not only affect our profitability, but also can cause customers to see our product as lower quality.
Causes of Leaks
1.
2.
3.
4.
Leaks result from two (2) causes: Human error and defective parts.
Failure to properly oil flares and flare joints.
Improper brazing.
Defective parts such as valves and compressors.
Before Charging a System
1. Before charging any system, set the pressure regulator at 300 PSIG. DO NOT EXCEED 300 PSIG WHEN
SETTING THE REGULATOR.
2. Any employee working around the system to be charged must wear safety glasses during initial charge.
3. Inform all employees that you will soon start charging the system and they are required to wear safety glasses.
Pressurizing Procedures
1. Set regulator at 300 PSIG.
2. Never open the nitrogen tanks to bleed through the Freon tank without first opening the outlet side of the Freon
tank into the system to be charged.
3. Slowly open the valve on the nitrogen tank to start pressurizing.
4. Never use the regulator as a shut-off valve. Use the tank valve.
| Leak Testing 23
Personal Protective Equipment
I. Purpose. The Personal Protective Equipment Plan provides direction to managers, supervisors, and employees
about their responsibilities in the selection, use, care and disposal of personal protective equipment.
II. General. Personal protective equipment and devices should be used only when it is impossible or impractical to
eliminate a hazard or control it at its source through engineering design. Wearing personal protective equipment does
not eliminate the hazardous condition. Every effort will be made to first eliminate the hazardous condition through
engineering and/or administrative control strategies. If it is not possible or feasible to eliminate hazardous conditions,
personal protective equipment will be used to establish a barrier between the exposed employee and the hazard to
reduce the probability and severity of an injury.
III. Responsibility and accountability.
A. Managers are responsible to ensure supervisors conduct worksite/task analyses to identify hazardous conditions
that may or may not be eliminated through engineering or administrative controls. In those tasks that expose
employees to hazardous conditions which cannot be eliminated through engineering or administrative controls,
managers will implement and monitor this Plan to ensure area supervisors are properly training, supervising and
enforcing PPE safety rules.
B. Supervisors are responsible, if directed, to carry out the provisions of this plan. They will:
a. Conduct worksite/task analysis initially and as needed to assess the need for personal protective equipment.
Sources of hazards include:
i. Hazards from impact/motion, high/low temperatures, chemicals, materials, radiation, fall
objects, sharp objects, rolling or pinching objects, electrical hazards, and workplace layout.
b. Certify in writing the tasks evaluated, hazards found, and actions recommended: Engineering controls,
administrative controls, PPE.
c. Select appropriate PPE. If a task exposes an employee to hazards which can not be eliminated through
engineering or administrative controls, the supervisor will identify and select PPE suitable for the specific
task performed, conditions present, and frequency and duration of exposure.
i. Supervisors are encouraged to take advantage of the services provided by OSHA consultants,
our workers’ compensation insurer consultants, private consultants and PPE suppliers for
expert assistance in selecting PPE.
ii. Supervisors should invite exposed employees to participate in PPE selection. Employees
need to give feedback to the supervisor about the fit, comfort, and suitability of the PPE
being selected.
d. Train exposed employees before they are assigned to the hazardous task.
a. Training should include:
i. When PPE is necessary;
ii. What PPE is necessary;
iii. How to properly don, doff, adjust, and wear PPE;
iv. The limitations of the PPE; and
v. The proper care, maintenance, useful life, and disposal of the PPE.
b. After the employee(s) demonstrate correct use, care, and disposal procedures of the PPE, the
supervisor and employee will certify completion of training.
e. Supervise employees on safe use and care of PPE. Supervisors will regularly monitor employees for
correct use and care of PPE, and provide follow-up training if required to ensure each employee has adequate
skill, knowledge, and ability to use PPE.
| Personal Protective Equipment 24
f.
Enforce PPE safety rules. Supervisors will enforce PPE safety rules following provisions of the company
progressive disciplinary procedures.
C. Employees. Employees are accountable to comply with PPE safety rules including:
a. The correct use and care of PPE.
b. Reporting changes in exposure to hazardous conditions that might require a follow-up analysis of the task for
PPE.
c. Reporting and replacing defective PPE.
IV. Selection Guidelines.
A. Eye and Face Protection. Employees must use appropriate eye or face protection when exposed to eye or face
hazards from flying particles, molten metal, liquid chemicals, acids or caustic liquids, chemical gases or vapors, or
potentially injurious light radiation. Eye and Face PPE must comply with ANSI Z87.1-1989.
a. It is our policy to make available safety eyeglasses that conform to ANSI Standard Z87.1 to all employees
and visitors who enter the factory floor and any other areas designated by the Company.
b. Type of Eyewear Permitted
i. Selection of safety eyewear, prescription or non-prescription, is limited to lenses that
conform to the above-referenced ANSI code and the frame selection as designated by the
Company.
ii. Safety eyewear for normal use is clear lenses mounted in safety frames with either permanent
or temporary side shields. Photogray lenses and contact lenses cannot be worn in designated
safety eyewear areas. Contact lens wearers must use appropriate safety eyewear.
iii. Employees wishing to upgrade their frame selection may do so provided that the frames meet
the appropriate ANSI code and can be equipped with side shields.
iv. Managers and supervisors must be able to see employee’s eyes at all times. Tinted safety
glasses that prevent managers and supervisors from seeing employee’s eyes are strictly
prohibited.
c. Who Must Wear Safety Eyewear
i. All employees must wear safety eyewear when entering the production floor. Areas of the
factory designated as safety glass areas shall include all departments and yellow painted
aisles. Face shields are required when using a grinder, wiz wheel cutter, and copper chop
saws. In addition, all visitors and contractors ( see specific sections for each ) are required to
wear safety eyewear when entering factory floor.
ii. All eligible employees (non-probationary) will be allowed one pair of ANSI approved, clear
lens safety eyewear per year. Employees eligible for prescription safety eyewear must meet
the above eligibility and must keep a current eyeglass prescription on file in the employee
file. Prescription changes will be honored for new safety eyewear every two (2) years. The
Company will subsidize the purchase of prescription safety eyewear to cover up to $70.00
for single vision, $90.00 for bifocal vision, and $100.00 for trifocal vision, of the purchase
price of this safety eyewear. Probationary (non-eligible) employees will be issued temporary
safety eyewear or safety goggles at the discretion of the Company.
d. Specialty Eyewear
i. Employees assigned to brazing departments will be entitled to two (2) pairs of safety
eyewear. One pair will be ANSI approved tinted lens (#5) brazing eyewear with permanent
side shields. The other pair will be our standard clear lens safety eyewear. These employees
are required to maintain both pairs of glasses at work.
e. Who Checks if You Are Wearing Safety Eyewear
i. The employee’s immediate manager or supervisor will verify that each individual in his/her
department possesses and wears appropriate safety eyewear while on the production floor.
f.
What Happens if You Do Not Wear Safety Eyewear
i. Failure to report to work with safety eyewear, failure to wear safety eyewear on the
production floor or careless or abusive use of safety eyewear may result in progressive
disciplinary action, up to and including termination for flagrant violation.
g. Replacement of Damaged or Lost Safety Eyewear
i. Safety, non-prescription, eyewear damaged through company-related work will be replaced
immediately upon the return of the damaged pair to the tool crib. Prescription safety
eyewear damage through company-related work should be replaced at the employee’s
expense. The Company will subsidize such replacement at 100%, provided the damage
accident is reported to the employee’s supervisor before the end of that day’s shift and the
damage is work-related. Safety eyewear lost or damaged through non-production related
work must be replaced at the employee’s expense. Should an employee lose or forget his/her
safety eyewear, the employee’s supervisor will issue a temporary replacement. Temporary
replacement eyewear must be returned to the supervisor at the end of the day and should not
be issued for more than two (2) consecutive days. Permanent replacement of either nonprescription or prescription safety eyewear, damaged through non-work related activity or
loss will be at the employee’s expense.
h. Visitor Eyewear Requirements
i. All visitors entering the factory floor are required to wear approved safety eyewear. It is the
responsibility of the host to ensure that all visitors are properly equipped with companyapproved safety eyewear before their entry onto the factory floor. Visitors’ eyewear may be
obtained either from the receptionist area or from the designated dispenser at the entrance to
the factory floor. It is also the responsibility of the host to be sure that this safety equipment
is returned to the proper location.
i.
Contractor Requirements
i. Contractors who are retained to work at Hill PHOENIX are subject to the same safety
eyewear regulations that regular Hill PHOENIX employees are. It is the responsibility of the
contractor to supply his/her employees assigned to work on the factory floor with ANSI
approved safety eyewear. The enforcement of this provision is the responsibility of the Hill
PHOENIX employee charged with the overall responsibility for the contracted project.
B. Head Protection. Employees must wear protective helmets when working in areas where there is a potential for
injury to the head from employee initiated impact or impact from falling or other moving objects. Protective helmets
designed to reduce electrical shock hazards will be worn by each employee when near exposed electrical conductors
which could contact the head. Helmets will comply with ANSI Z89.1-1986 or be equally effective.
C. Foot Protection. Employees must wear protective footwear when working in areas where there is a danger of foot
injuries due to falling or rolling objects, or from object piercing the sole, and where employees’ feet are exposed to
electrical hazards. PPE for foot protection must comply with ANSI Z41.1991 or be equally effective.
a. All employees should wear a leather-type shoe. Canvas is NOT acceptable. Hill PHOENIX recommends
employees wear steel toed safety shoes, the Company will subsidize the purchaser $25.00 once every twelve
(12 ) months.
D. Hand Protection. Employees must use appropriate hand protection when their hands are exposed to hazards such
as those from skin absorption of harmful substances; severe cuts or lacerations; severe abrasions; punctures; chemical
burns; thermal burns and harmful temperature extremes. ALL employees handling sheetmetal must wear the
appropriate gloves. Supervisors must base the selection of hand protection on evaluation of the performance
characteristics of the hand protection relative to the specific tasks to be performed, conditions present, duration of use
and the hazards and potential hazards identified.
E. Respiratory Protection. Employees will wear appropriate respiratory protection when adequate ventilation or
substitution with non-toxic chemicals, etc., is not possible or feasible. Respirator protection must comply with ANSI
Z288.2-1969.
F. Fall Protection. Fall protection must be provided when employees are exposed to (1) a vertical fall of ten feet or
more over a lower level or (2) any height over dangerous equipment. Fall protection will consist of either passive or
active fall protection. Fall protection must comply with ANSI A10.14-1991.
G. Electrical Protection. Electrical protective equipment such as insulating blankets, mating, covers, line hoses,
gloves, gloves and sleeves must be provided to employees who are exposed to electrical hazards.
V. Monitoring.
A. Managers will monitor worksite tasks for changes in, or the introduction of new hazards. If new hazards are
discovered, they will conduct a task analysis for appropriate PPE. A worksite analysis will be conducted at
least annually for each task that requires employees to use PPE.
B. The safety committee will monitor the effectiveness of this Plan and make recommendations to management
to improve the plan.
All manufacturing employees are required to wear full-length pants of a fabric similar to the density and
rigidness of denim or work pants. Shirts are required to completely cover the stomach, sides and back.
Employees should wear a leather-type shoe. Canvas is NOT acceptable. **As an employee, you have the
ultimate responsibility to wear your equipment as well as care for it.**
Hearing Conservation Program
I. Scope
Hill PHOENIX will administer a continuing, effective Hearing Conservation Program as described in these
procedures whenever employee exposure to noise during work operations at Hill PHOENIX equals or exceeds an 8hour time-weighted average (TWA) of 85 decibels (“dba”) measured by OSHA standards. This level of sound will
be designated the “action level” in accordance with OSHA regulations.
II. Permissible Noise-Exposure Limits
Any noise level equal to or in excess of 85 dba over an 8-hour TWA (the action level) will trigger Hill PHOENIX’s
responsibility to adhere to the procedure outlined in Hill PHOENIX’s written Hearing Conservation Program.
The permissible exposure for employees who have experienced a decrease in hearing sensitivity is an 8-hour TWA of
85 dba.
III. Table of Permissible Noise Exposure Guidelines
Duration
Per Day/Hours
**8
8
6.1
4
3
2
1.5
1
.76
.50
.33
.25
Sound Level
/ DBA
**85
90
92
95
97
100
102
105
107
110
112
115
** 85 dba/8 hours - Level at which a Hearing Conservation Program is put into effect.
IV. Area Monitoring
Whenever information indicates that any employee’s occupational exposure to noise equals or exceeds the action
level, Hill PHOENIX shall conduct area monitoring to determine the noise levels at issue.
As necessary, Hill PHOENIX will hire an outside consultant, which will conduct area monitoring and/or
representative personal sampling and report to the Director of Human Resources the results of such monitoring.
Area monitoring and/or representative personal sampling shall be conducted whenever a change of production,
process, equipment or controls increases noise exposure such that employees not currently participating in Hill
PHOENIX’s Hearing Conservation Program may be exposed to noise at or above the action level, or when any
hearing protection currently being worn by employees may be rendered inadequate because of sound levels in excess
of 90 dba.
| Hearing Conservation Program 28
Human Resources will be responsible for identification of the high-noise areas around the Plant and all recordkeeping
pertaining thereto. “High-noise areas” are those areas of the Plant where area monitoring reveals that noise exposure
equals or exceeds the action level.
Where sound levels equal or exceed 85 dba TWA, area monitoring will be repeated every two (2) years or when
operations are significantly changed, such that noise levels might be affected. Noise levels will be measured within
thirty (30) working days in all areas where such a change in equipment or type of operations has occurred. The
Safety Manager shall determine if additional area noise surveys are warranted.
When area monitoring reveals that employees are exposed to noise levels at or exceeding the action level, those
employees so exposed shall be notified by the Human Resources Department by a written notice informing them that
they are required to participate in Hill PHOENIX’s Hearing Conservation Program.
V. Noise-Control Measures
When noise levels equal or exceed the action level, those employees exposed to such noise levels who have not yet
had a baseline audiogram established or who have experienced hearing loss of a “standard threshold shift” (STS) are
required to wear hearing protection at all times during work operations when they will be exposed to such noise
levels. The use of hearing protectors by all employees exposed to such noise levels equal to or exceeding the “action
level” is mandatory.
A “standard threshold shift” (STS) is defined as a change in hearing threshold relative to a baseline audiogram of an
average of 10 dba or more at 2,000, 3,000, or 4,000 Hz in either ear, as set forth at 29 CFR 1910.95 (g) (10).
In the event an STS is identified, the employee involved will be required to wear hearing protection. Employees
already using hearing protection will be refitted and retained in the use of hearing protective devices and provided
with hearing protectors offering greater safety if necessary.
Employees exhibiting an STS shall be referred to a physician or audiologist if Hill PHOENIX determines that:
• Additional testing is necessary
• Hill PHOENIX suspects that a medical problem in the ear is aggravated or caused by the use of
hearing protection
• If it appears that a medical pathology of the ear is unrelated to the use of hearing protective devices.
Whenever employees are subjected to noise levels exceeding an 8-hour TWA of 90 dba, feasible engineering,
administrative and/or hearing protection controls should be taken where necessary to reduce employee exposure to
noise.
VI. Employee Complaint Evaluation
Human Resources will respond to employee complaints regarding noise and will determine the action necessary to
address the complaint.
VII. Procedures Governing High-Noise Areas
Signs or other markings indicating equipment and areas of high noise will be clearly posted to ensure that employees
will be aware where hearing protection must be worn. To ensure complete visibility, signs shall be kept clean and
unobstructed.
All employees participating in Hill PHOENIX’s Hearing Conservation Program must wear hearing protection
during all work operations. All employees who routinely work in areas of the Plant where signs are posted requiring
the wearing of hearing protection must wear hearing protection during work operations. Also, any employee passing
through an area where signs designate that hearing protection must be worn must wear hearing protection while
traveling through that area. Generally, travel through high noise areas is to be avoided.
It is permissible to briefly remove hearing protective devices off the ear for communication with other employees.
Employees who have exhibited a “standard threshold shift” will be provided with and required to wear hearing
protection in accordance with OSHA regulations, 29 CFR 1910.95 (g) (8) (ii) (B).
Failure to wear hearing devices as required will result in counseling and corrective action. Employees who complain
that they cannot wear hearing protective devices for medical or other reasons must be referred to the Human
Resources Department for a consultation.
VIII. Distribution of Hearing Protective Devices
Hill PHOENIX will make hearing protective devices available to all employees exposed to an 8-hour time weighted
average of 85 decibels or greater at no cost to the employee.
The Human Resources Department shall supply hearing protective devices to those Department Managers with
supervision over employees working in those areas of the Plant where the use of hearing protection is required.
Special hearing devices will be distributed through the Human Resources Department.
IX. Employee Training
Training shall conform to OSHA standard 1910.95(k)(1) through (3)(i) through (iii)
X. Audiometric Testing
The Human Resources Department will be responsible for scheduling audiometric testing annually. Examinations
will be given to all employees assigned to work in areas where noise level equals or exceeds the action level.
•
•
•
All employees participating in Hill PHOENIX’s Hearing Conservation Program will be tested once a
year.
All newly hired employees exposed to noise levels equal to or exceeding the action level who have not
been given a baseline audiometric test will be required to take such a test at the next scheduled testing
date after their hire.
All employees who have transferred to or been assigned to work operations in a high noise area
(defined as an area where noise levels equal or exceed 85 dba on an 8-hour TWA) will be given an
audiometric baseline test within six months of their first exposure to such noise levels, or shall wear
hearing protection for any period of time exceeding six months from their first exposure until a
baseline audiogram is obtained.
On the day a hearing test is scheduled, it is the responsibility of the Department Supervisor to ensure that scheduled
employees attend the tests at their scheduled times and locations. Employees who refuse to be tested will be subject
to discipline, up to and including discharge.
The Human Resources Department shall maintain a file on audiometric test results, which shall include:
•
•
•
•
•
•
Name and Job Classification of employee tested;
Date of Audiogram
Examiner’s name
Date of the last acoustic or exhaustive calibration of the audiometer
Employee’s most recent noise exposure assessment; and
Record of the measurements of the background sound pressure levels in the audiometric testing equipment.
The Human Resources Department will maintain the records of the annual audiograms for the duration of each
employee’s employment.
Respiratory Protection Program
I. Purpose
Respirators shall be worn when effective engineering controls are not feasible to provide adequate protection for
employees from atmospheric contamination according to OSHA Guidelines 1910.11-12.
II. Scope
Respirator protection for employees shall be made according to the guidance of American National Standard
Practices for Respiratory Protection Z88.2-1992. Respirator protection shall be used by Hill PHOENIX employees
that fall under the guidelines of this program.
Hazards to the lungs are not always easy to detect. Some of the most common hazards are lack of oxygen and
presence of harmful dust, fogs, smokes, mists, fumes, gases, vapors, or sprays including substances which may cause
cancer, lung impairment, other diseases or death. Respirators prevent entry of harmful substances into the body
during breathing and make sure that the user has an adequate supply of clean air. Some respirators also provide a
separate supply of air so work can be done where there is inadequate oxygen.
Prevention of atmospheric contamination at the work site generally should be accomplished as feasibly as possible by
engineering control measures (for example, enclosure or confinement of the contaminate producing operation,
general and local ventilation) or by work practice controls such as substitution of less toxic materials. Historically,
the industrial hygiene profession has sought to control hazardous air contamination through engineering or work
practice means. However, when effective engineering controls are not feasible, or while those controls are being
installed, appropriate respirators must be used. The user should be aware that respirators have their limitations and
are not a substitute for effective engineering controls. Where respirators are necessary for health protection, specific
procedures are necessary to overcome potential deficiencies and to ensure effectiveness.
Hill PHOENIX will be responsible for establishing an effective respiratory program. Hill PHOENIX employees will
be responsible for wearing the respirator and complying with the program.
III. Guidelines
1.
Employees in the following areas will be trained in proper use, selection and maintenance of respirators:
a)
b)
2.
Paint Department
Other Employees as determined by exposure
Before being assigned to tasks requiring use of a respirator, a medical evaluation will be given to determine
if the employee is physically able to perform the work and use the equipment. Contact the Human Resources
Department for the name of the physician. The medical evaluation form will be forwarded to Hill PHOENIX
upon completion and kept in the employee’s medical file in the Human Resources Department.
| Respiratory Protection Program 32
IV. Respirator Designations
1.
Respirators are required to perform the following tasks. The type of respirator and filter shall be specific for
each application.
a)
2.
3.
4.
Painters: A Non-Oil air-purifying half-mask type is required by all persons in the paint booth when
painting is in process.
i)
Respirator: 3M-7200, 7300, 7200 S or equivalent.
ii)
Approved Pre-filters: CAP 3M-7287 or equivalent.
iii)
Approved Cartridges: 7N11-Filter Cart-Non-Oil or equivalent.
Indoor air sampling and personal air-monitoring has determined that respirators are not required in the
following areas. During the monitoring, the OSHA PEL (Permissible Exposure Limit) was not exceeded on a
time-weighted averaging basis. However, during periods of peak equipment usage and/or production
extremes, the containment levels may be of an irritant in nature and respiratory protection is recommended at
that time.
a)
Paint Prep: An air-purifying half-mask type is recommended when using solvent and/or sanding
painted surfaces.
i)
Respirator: 3M-7200, 7300 or equivalent.
ii)
Approved Cartridges: 7N11-3M or equivalent.
b)
Miscellaneous Use: Occasionally a machining or manufacturing operation may generate excessive
smoke, particulate, fumes, gases, mists, and vapors that may be irritants. It is recommended that
disposable respirators be worn when any of the above contaminants are suspected.
i)
Disposable Type: 3M-8710, 9900, 9970 or equivalent.
The Respirator designations are guidelines based on test results and approved methods. Should
circumstances arise that are not covered in these designations, consult a supervisor or the Human Resources.
Remember: Ask BEFORE the suspected exposure.
A respirator selection chart is listed as Appendix B which reflects Section IV Respirator Designation
Information and has been developed for user convenience.
V. Selection of Respirators
1. The respirators shall be selected based on the type of hazard to which the worker is exposed.
2. Proper selection of respirators shall be made according to the guidance of American National Standard Practices
for Respiratory Protection A88.2-1992.
Several factors will be considered when selecting a respirator: the chemical and physical nature of contaminants; the
toxicity and concentration of the contaminants; the amount of oxygen present in the atmosphere; the nature and
extent of the hazard; and the amount of area to be covered, and oil or non oil.
VI. Types of Respirators
1. Air Purifying: Used when there is enough oxygen present but the air is contaminated with gasses, vapors, dust,
etc. They are designed to remove harmful substances from the air
2. Air Supplying: Used when there is not enough oxygen in a confined space or area when the concentration of
airborne substances that are present is immediately dangerous to life or health. They are designed to provide air
from a clean source outside of the contaminated work area.
VII. Use of Respirators
1.
Every respiratory wearer shall receive fitting instructions including demonstrations and practices on how the
respirator shall be worn, how to adjust it, and how to determine if it fits properly.
2.
Employees required to use respirators will receive training on an annual basis in the proper use and
limitations of respirators. The training program shall include the following:
a)
b)
c)
d)
The nature of the respiratory hazards in the workplace and how to select the correct respirator.
Use of respirator and proper fitting.
Capabilities and limitations of respirators.
Emergency use of respirators.
3.
All respirator training shall be provided as needed by Human Resources.
4.
A training checksheet will be filled out to certify proper training and will be put in the employee’s file in the
Human Resources Department.
VIII. Maintenance and Care for Respirators
1.
All respirators shall be inspected routinely before and after each use. Special attention should be given to
rubber parts, which can deteriorate. The face piece, especially the face seal surface, headband, valves,
connecting tube, fittings, and canister must be in good condition. A respirator not routinely used but kept for
emergency use shall be inspected after each use and at least monthly to ensure that it is in satisfactory
condition.
2.
Self-contained breathing apparatus shall be inspected monthly. Air and oxygen cylinders shall be fully charged
according to manufacturer’s instructions.
3.
A record shall be kept of inspection dates and findings for respirators maintained for emergency use.
4.
After each use respirators shall be cleaned, inspected and disinfected to ensure that proper protection is
provided.
5.
Only trained persons using parts designed for the respirator shall do replacement or repairs.
6.
A supply of respirator replacement parts shall be available in the Hazardous Materials Cabinet in the Paint
Room.
7.
Respirator cleaning and disinfecting supplies will be available in the Paint Room.
8.
Facilities for washing respirators are available in the Paint Room.
9.
Disposable respirators are available from the tool crib.
10.
Pre-filters and filter cartridges will be available in the Tool Crib.
11.
It is the responsibility of the Plant Operations to maintain all supplies associated with respirator maintenance
and to carry out the necessary inspections.
12.
Respirators will be stored to protect against dust, sunlight, heat, extreme cold, excessive moisture, or damaging
materials. Protection against any mechanical damage will also be provided. Respirators will be stored so that
face pieces and exhalation valves will rest in a normal position to prevent the rubber or plastic from reforming
in an abnormal shape.
IX. Fitting Procedures for Half-Mask Respirator
1.
2.
To ensure proper fit, the following methods shall be used:
a)
Positive Pressure Check - Place palm of hand over exhalation valve and exhale gently. If face piece
bulges slightly and no air leaks between face piece and face, a proper fit has been achieved.
b)
Negative Pressure Check - Place hand over inhalation valves and gently inhale. If face piece
collapses slightly, a proper fit has been achieved.
The positive and negative pressure checks should be done each time a respirator is put on. A pressure check
cannot be performed with a disposable respirator.
3. Both straps must be in place around the wearer’s head for a disposable type respirator to be effective as stated by
OSHA.
X. Employee Training
Training shall conform to OSHA standard 1910.34(k)(1)(i) through (viii); (2), (3), and (5)(i) through (iii)
Manufacturing Operations
Manufacturing operations cover a wide range of topics. This includes forklifts, overhead cranes, manlifts, machinery
and machine guarding, hand-held portable and power tools, and welding, cutting and brazing operations.
I. Powered Industrial Trucks: Forklifts and Manlifts
To ensure a safe working environment, Hill PHOENIX requires that only trained employees shall operate forklifts
and manlifts. Trained employees are issued a certification card.
Procedure
1. All powered industrial trucks and manlifts must bear a label or some other identifying mark indicating approval
by ANSI.
2. All nameplates and markings must be maintained in a legible condition.
3. Only trained and authorized operators shall be permitted to operate a powered industrial truck or manlift.
4. Any powered industrial truck not in safe operating condition shall be removed from service. Authorized
personnel shall make all repairs.
5. Maintenance of industrial trucks shall follow manufacturer’s recommendations.
6. A record of the scheduled maintenance must be kept with the Maintenance Department Supervisor.
II. Overhead Cranes
Hill PHOENIX requires that only trained and qualified employees operate and perform maintenance functions on the
overhead cranes. Trained employees are issued a certification card.
Procedure
Before Operating
•
•
All rigging must be clearly marked with load capacity.
All crane operators must inspect the crane before using to ensure safe-operating condition. These inspection
points include:
•
•
•
•
•
•
•
Cables for frays
Slings for wear and frays
Pendant controls
Testing safety limits before attaching
the load
•
•
•
•
Hooks for wear and cracks
Spreader bars for wear
Chains for wear and cracks
To ensure alignment of cable on
hoist drum
Inspect the area for obstacles in the path of the load and operators.
Operators must know the (1) total weight of the load to be lifted, (2) the calculated load at each point of lift, and
(3) the center of balance for the lift.
Hoists are designed for straight, vertical pulls; therefore, the rigging must be attached so that the hoist cables are
vertical.
| Manufacturing Operations 36
Making the Lift
1.
2.
3.
4.
Gently remove slack from the hoist cable and raise the load just high enough to check the balance.
Never make a lift without having two full cable wraps on the hoist drum, regardless of the width of the load.
Avoid sudden starts and stops and do not ram runway stops.
Never carry a load or rigging over any person or allow anyone to ride the hoist or crane.
Maintenance
Crane maintenance is based upon the manufacturer’s recommendations. An annual inspection is performed by an
authorized service company.
Lockout/Tag-out
Any person or persons using the overhead cranes shall institute lockout/tag-out procedures.
III. Hand and Portable Powered Tools and Equipment
In order to ensure safety in all phases of our manufacturing operations, all tools and equipment used by employees
must be properly maintained in a safe working condition.
Procedure
OSHA regulations state that the employer is responsible for the safe condition of tools and equipment used by
employees, including ones that are furnished by employees. Supervisors will inspect these tools daily for the
following:
1. All portable powered tools shall be equipped with safety guards recommended by the manufacturer.
2. Hand held power tools must have the required switches and controls.
3. Operators and assistants using nail guns or similar equipment that propels an object must use safety glasses.
4. Before using a tool, the operator shall inspect it to determine that it is clean, that all moving parts operate freely,
and that the barrel is free from obstructions.
IV. Welding, Cutting and Brazing
Some of the most dangerous activities at Hill PHOENIX involve welding, cutting, and brazing. Therefore, all
employees involved with welding, cutting and brazing operations shall receive instruction covering all aspects of
these operations. This includes fire protection and personal protection, instruction on arc welding and cutting,
brazing, storage handling and conveyance of acetylene, oxygen, nitrogen, and carbon dioxide.
Procedure
1. Team leaders, manager, or supervisors must first instruct employee(s) in the compressed gas section of this
manual.
2. Any operator or installer of oxygen-fuel gas systems for welding and cutting must first receive training in these
3. Team leaders, manager, or supervisors in charge of piping systems must ensure that the isolation valves, hoses
and regulators are maintained on a regular basis.
Operation and Maintenance
1. Before starting operations, all connections to the machine must be checked to ensure proper working condition.
2. Operator must make sure the welding machine is properly grounded.
3. All manufacturers’ instructions covering operations and maintenance shall be strictly followed.
4. Any equipment defect or safety hazard should be promptly reported to a supervisor. Only qualified personnel
shall make repairs.
5. Cables with damaged insulation or exposed bare conductors shall be replaced immediately.
Personal Protection
1. Helmets or hand shields must be used during all welding and cutting operations.
2. Goggles or other eye protection must be worn during all gas welding operations.
3. Employees exposed to the hazards of welding, cutting, or brazing shall wear the required protective equipment
and clothing. This includes hearing protection, foot protection, face shields, and brazing goggles.
Grinding Safety
Protective Equipment
Before using any type of grinder, you must use the proper personal protective equipment. This equipment includes:
•
•
•
Safety Glasses
Face Shields
Gloves
Inspections
1. All grinders and grinding wheels must be inspected before operations.
2. Visually inspect the grinding wheel for any cracks and damage.
3. Examine the retainer nuts to ensure that the grinding stone is securely fastened.
Operation
1. Always hold the grinder with a tight, secure grip.
2. Only use the flat portion of the grinding disc for portable grinders. Do not use the edge of the disc.
3. For welds, grind the length of the weld, not across.
4. Use smooth and gradual movements when grinding.
5. When the grinding stone is cold, start slowly to heat the stone.
6. Never drop the grinding wheel or disc.
7. Keep the grinding wheel away from oil, water, grease, etc., because the stone will absorb these materials.
Preventing Kick-Back
•
•
•
•
The main cause of kick-back on portable grinders comes from improper use of the grinding stone:
Using the edge of the disc or stone instead of the bottom surface area.
Also, use the section of the wheel or disc in front of the grinder, not on the left or right side.
Applying too much force on the disc or stone can cause kickback. Always grind gradually and smoothly.
| Grinding Safety 39
Spray Finishing Operations
OSHA has numerous requirements for the design, construction, and operation requirements for location and
ventilation. Following these guidelines will drastically reduce the fire risks and health hazards associated with
operating a spray booth.
Procedures:
1. For cleaning purposes, a clear space of at least three (3) feet on all sides of the spray booth shall be kept from
storage or combustible construction.
2. Any electrical equipment in the spraying area must have the wiring in rigid conduit or boxes or fittings
containing no taps, splices or terminal connections.
3. Flammable and combustible liquids kept inside the spray room will be kept to a minimum to not exceed one
day’s supply. Bulk storage of portable, flammable liquids must be in a separate area, away from the paint room.
4. Sprinklers protecting the spraying areas must be inspected routinely and cleaned as needed to prevent deposit
build-up.
5. All spraying areas must be routinely cleaned to keep combustible residue build-up to a minimum.
6. All employees working in spray finishing operations must wear personal protection equipment. This equipment
includes NIOSH/MSHA approved respirator and eye goggles.
| Spray Finishing Operations 40
Safety Training Manual
Training
Fire Extinguisher
Training Frequency: Required Annual Training
Haz-Comm
Bloodborne Pathogens
Lockout/Tag Out
Compress Gas Training
Training Frequency: At orientation; upon assignment to new area
Respirator Training
PPE Training
Training Frequency: At orientation; upon assignment to new area; change in PPE
Machine Guarding
Training Frequency: At orientation, upon assignment to new area
Working Surfaces: Falls
Electrical Safety
Ladder Safety
Hearing Conservation
Workplace Violence
Forklift Safety Training
Training Frequency: Required Training to obtain Forklift Licenses; recertification every 3 years.
| Safety Training Manual 41
Fire Extinguisher Training
Fire safety, at its most basic, is based upon the
principle of keeping fuel sources and ignition
sources separate.
Three things must be present at the same time to produce fire:
1. Enough Oxygen to sustain combustion
2. Enough Heat to reach ignition temperature
3. Some Fuel or combustible material
Together, they produce the chemical reaction that is fire. Take away any of these things and the fire will be
extinguished.
FUEL CLASSIFICATIONS
Fires are classified according to the type of fuel that is burning. If you use the wrong type of extinguisher on the
wrong class of fire, you might make matters worse. It is very important to understand the four different fire (fuel)
classifications:
Class A: Wood, paper, cloth, trash, plastics—solids that are not metals.
Class B: Flammable liquids—gasoline, oil, grease, acetone. Includes flammable
gases.
Class C: Electrical—energized electrical equipment. As long as it is “plugged in.”
Class D: Metals—potassium, sodium, aluminum, magnesium. Requires Metal-X,
foam, and other special extinguishing agents.
Most fire extinguishers will have a pictograph label telling you which types of fire the extinguisher is designed to
fight.
| Fire Extinguisher Training 42
For example, a simple water extinguisher might have a label like
this, which means it should only be used on Class A fires.
TYPES OF FIRE EXTINGUISHERS
Different types of fire extinguishers are designed to fight different classes of fire. The three most common types of
fire extinguishers are:
1. Water (APW)
Large, silver fire extinguishers that stand about
2 feet tall and weigh about 25 pounds when
full.
APW stands for “Air-Pressurized Water.”
Filled with ordinary tap water and pressurized
air, they are essentially large squirt guns.
APW’s extinguish fire by taking away the “Heat” element of the Fire Triangle.
APW’s are designed for Class A fires only: Wood, paper, cloth. Here are a couple of reasons you need to be
careful about which extinguisher you use:
Using water on a flammable liquid fire could cause the fire to spread.
Using water on an electrical fire increases the risk of electrocution. If you have no choice but to use
an APW on an electrical fire, make sure the electrical equipment is unplugged or de-energized.
APW’s will be found in older buildings, particularly in public hallways, as well as in residence halls on
campus. They will also be found in computer laboratories. It is important to remember, however, that
computer equipment must be disconnected from its electrical source before using a water extinguisher on it.
2. Carbon Dioxide (CO2)
The pressure in a CO2 extinguisher is so
great, bits of dry ice might shoot out of
the horn!
CO2 cylinders are red. They range in size from 5 pounds to 100 pounds or larger. On larger sizes, the horn
will be at the end of a long, flexible hose.
CO2’s are designed for Class B and C (flammable liquids
and electrical sources) fires only!
CO2’s will frequently be found in laboratories, mechanical rooms, kitchens, and flammable liquid storage
areas.
In accordance with NFPA regulations (and manufacturers’ recommendations) all CO2 extinguishers at OSU
undergo hydrostatic testing and recharge every five years.
Carbon dioxide is a non-flammable gas that takes away the oxygen element of the Fire Triangle. CO2 is very
cold as it comes out of the extinguisher, so it cools the fuel as well.
A CO2 may not be very effective in extinguishing a Class A fire because it may not be able to displace
enough oxygen to successfully put the fire out. Class A materials may also smolder and re-ignite.
3. Dry Chemical (ABC, BC, DC)
ABC extinguishers are red. On campus, they
range in size from five pounds to 20 pounds.
On the OSU campus, ABC extinguishers are filled with a fine, yellow powder. This powder is mostly
composed of monoammonium phosphate. The extinguishers are pressurized with nitrogen.
Dry chemical extinguishers put out fire by coating the fuel with a thin layer of dust. This separates the fuel
from the oxygen in the air. The powder also works to interrupt the chemical reaction of fire. These
extinguishers are very effective at putting out fire.
Dry chemical extinguishers come in a variety of types. You may see them labeled:
DC (for dry chemical)
ABC (can be used on Class A, B, or C fires)
BC (designed for use on Class B and C fires)
It is extremely important to identify which types of dry chemical fire extinguishers are located in your area!
An “ABC” extinguisher will have a label like this,
indicating it may be used on Class A, B, and C fires.
You don’t want to mistakenly use a “BC” extinguisher on a Class A fire thinking that it was an “ABC”
extinguisher.
Dry chemical extinguishers with powder designed for Class B and C fires (“BC” extinguishers) may be
located in places such as commercial kitchens and areas with flammable liquids.
On campus you will find ABC’s in public hallways of new buildings, in laboratories, break rooms, offices,
chemical storage areas, mechanical rooms, University vehicles, etc.
HOW TO USE A FIRE EXTINGUISHER
It is easy to remember how to use a fire extinguisher if you remember the acronym, “PASS.”
Pull
Aim
Squeeze
Sweep
Pull the pin
This will allow you to discharge the extinguisher.
Aim at the base of the fire
Hit the fuel…if you aim at the flames, the extinguishing agent
will pass right through and do no good.
Squeeze the top handle
This depresses a button that releases the pressurized
extinguishing agent.
Sweep from side-to-side until the fire is completely out.
Start using the extinguisher from a safe distance away and then
slowly move forward. Once the fire is out, keep an eye on the
area in case it re-ignites.
RULES FOR FIGHTING FIRES
Fires can be very dangerous and you should always be certain that you will not endanger yourself or others when
attempting to put out a fire. For this reason, when a fire is discovered,
1.
Assist any person in immediate danger to safety, if it can be accomplished without risk to yourself.
2.
Call 911 or activate the building fire alarm. The fire alarm will notify the fire department as well as other
building occupants and shut off the air handling system to prevent the spread of smoke.
If the fire is small (and Only after having done these two things), you may attempt to use an extinguisher to put it out.
However, before deciding to fight the fire, keep these things in mind:
Know what is burning. If you don’t know what is burning, you won’t know what kind of extinguisher to
use.
Even if you have an ABC fire extinguisher, there might be something in the fire that is going to explode or
produce toxic fumes.
Chances are you will know what is burning, or at least have a pretty good idea, but if you don’t, let the fire
department handle it.
Is the fire spreading rapidly beyond the point where it started? The time to use an extinguisher is at the
beginning stages of the fire.
If the fire is already spreading quickly, it is best to simply evacuate the building.
As you evacuate a building, close doors and
windows behind you as you leave.
This will help to slow the spread of smoke and
fire.
Do not fight the fire if:
You don’t have adequate or appropriate equipment.
If you don’t have the correct type or large enough extinguisher, it is best not to try fighting the fire.
You might inhale toxic smoke.
When synthetic materials such as the nylon in carpeting or foam padding in a sofa burn, they can produce
hydrogen cyanide, acrolein, and ammonia in addition to carbon monoxide. These gases can be fatal in very
small amounts.
Your instincts tell you not to.
If you are uncomfortable with the situation for any reason, just let the fire department do their job.
The final rule is to always position yourself with an exit or means of escape at your back before you attempt to use an
extinguisher to put out a fire.
In case the extinguisher malfunctions, or something unexpected happens, you need to be able to get out quickly. You
don’t want to become trapped.
FIRE EXTINGUISHER TRAINING QUIZ
1. An example of two “Class B” fuels would be:
a. Cardboard, newspapers
b. Lamp, hot plate
c. Grease, paint thinner
2. An APW (water extinguisher) is safe to use on an electrical fire.
a. True
b. False
3. Carbon Dioxide extinguishers are designed for which types of fuels?
a. Class B and C
b. Class A, B and C
c. Class A and C
d. Class A and B
4. Which type of extinguisher has a hard horn on the end of a flexible hose or metal arm?
a. APW (air-pressurized water)
b. CO2 (carbon dioxide)
c. ABC (dry chemical)
5. As a general rule, you should not attempt to fight a fire if it is spreading rapidly.
a. True
b. False
6. ABC fire extinguishers extinguish fire by cooling it down.
a. True
b. False
7. Water will not extinguish most flammable liquid fires.
a. True
b. False
8. You should always keep an exit or means of escape at your back when trying to fight a fire.
a. True
b. False
9. The three elements of the fire triangle are:
a. Water, a heat source, and fuel
b. Oxygen, water, and fuel
c. Oxygen, fuel, and a heat source
d. Fuel, oxygen, and earth
10. Do you know where the nearest fire extinguisher is in your work area?
a. Yes
b. No
Answers
1. C
2. B
3. A
4. B
5. A
6. B
7. A
8. A
9. C
10. A
Fire Extinguisher Training
Form
Name: ___________________________________________________
Employee Number: ______________
I have been trained in and understand the following: (Put initials to indicate appropriate areas trained).
Date of Training:
_________________
Person(s) who Performed Training: __________________________________
Initial
1.
2.
3.
4.
5.
Types of Fires
Types of Fire Extinguishers
Fire Extinguisher Inspections
Fire Extinguisher Maintenance
Use of Fire Extinguishers
_________
_________
_________
_________
_________
My signature indicates that I was trained on the “Fire Extinguisher Plan.” I further certify that I understand the
training that was presented to me and I know what is expected of me
Signed: ______________________________
Date: ______________
HAZARD COMMUNICATIONS
“YOUR RIGHT TO KNOW”
OSHA definition of Hazard Communications:
Your Right To Know
The Controlling of Hazardous Materials
OSHA requires that all associates receive Hazard Communications Training
Requires annual refresher training
Requires access to all MSDS’s
Requires monitoring as necessary
Requires specific training when introducing new product
Requires proper storage and disposal
Requires proper labeling and identification of all containers
MSDS - Material Safety Data Sheet
Required for all chemicals in the workplace
Made available to all associates 24/7
Centrally located to be accessed by all associates
MSDS’s provide:
– Chemical components
– Required PPE for use
– Exposure Limits
– First Aid measures
– Spill Clean-up procedures
– Disposal methods
– Manufacturer name and address
– Emergency phone numbers
MSDS Abbreviations:
– PEL, Permissible Exposure Limits - Amount associates can receive without injury
– TWA, Time Weighted Average - Amount of exposure in 8 hour period
– PPM, Parts Per Million - Measurement of exposure amount
– STEL, Short Term Exposure Limits - Can never be exceeded
– TLV, Threshold Limit Value - Maximum airborne concentration to which associates can be exposed
Hill PHOENIX responsibility:
All affected associates must made aware of chemicals they are working with.
Specific training provided if new chemical introduced
Must be certain MSDS available for all chemicals
Must be certain all chemicals are properly stored
Must be certain all containers are properly labeled
Associate responsibility:
Be aware of their right to know
Be aware of chemicals they are working with
Ask questions and for assistance if unsure
| HAZARD COMMUNICATIONS 52
Labeling of Containers
HMIS or Hazard Material Identification System
Each container must be properly marked with an HMIS Label.
Label must contain:
– Chemical given name
– Health hazard rating-BLUE
– Fire hazard rating-RED
– Reactivity rating-YELLOW
– PPE or special hazard rating-WHITE
Immediate Use Containers
Definition
– A container used to transfer chemicals from a main source to a smaller, easier to handle container for
immediate use such as:
Spray Bottle
Small easy to handle container
– Must be labeled as required
Chemical given name
Health hazard rating
Fire hazard rating
Reactivity rating
PPE or special hazard rating
Important issues to remember
Your Right To Know
– MSDS, their use and purpose
– Exposure Limits
– HMIS Labels and their importance
– Immediate use containers
It is not only the responsibility of the Company to inform the associates of the chemicals used in the workplace
but also the responsibility of the associate to be certain they are handling all chemicals safely.
_____1. OSHA Regulations on Hazard Communications says that?
A. Only certain chemicals can be used
B. Only chemicals that are used in large quantities need to be evaluated for hazards
C. All chemicals must be evaluated for their hazards and all information relating to these hazards must be made
available to all associates
D. Only chemical engineers are allowed to handle large quantities of chemicals
_____2. Material Safety Data Sheets (MSDS’s) must contain?
A. The identity of the chemical and the name, address, and the phone number of the manufacturer, importer, or
other responsible party
B. The physical characteristics and the physical health hazards
C. Control methods and precautions for safe handling and use
D. All the above
_____3. Copies of the MSDS’s must be?
A. Located where they can be accessed 24/7
B. Maintained at a central location where they can be accessed by associates
C. Attached to each container
D. Both a and b
_____4. Containers of hazardous chemicals must be labeled with an HMIS label detailing?
A. The identity of the chemical by it’s recognized name, hazard warnings, name and address of manufacturer,
importer or other responsible party
B. The phone number of the chemical manufacturer, importer, or other responsible party
C. The identity of the chemical and first aid procedures
D. The identity of the chemical, hazard warnings, and required personal protective equipment
_____5. OSHA defines Hazard Communications as?
A. Driving through ice and snow
B. Your Right To Know, The Controlling of Hazardous Materials
C. Operating of unguarded equipment
D. Marking areas throughout the facility that require Hearing Protection
My signature indicates that I was trained on “Hazard Communications.” I further certify that I understand the training
that was presented to me and I know what is expected of me
Signed: ______________________________
Date: ______________
BLOODBORNE PATHOGENS
If you can reasonably anticipate facing contact with blood and/or other potentially infectious materials as part of your job duties,
you should receive additional training from your instructor or supervisor including an opportunity for interactive questions and
answers. You should also read the summary of OSHA's bloodborne pathogen standard before continuing with this module.
Bloodborne Diseases
Bloodborne pathogens are microorganisms such as viruses or bacteria that are carried in blood and can cause disease in people.
There are many different bloodborne pathogens including malaria, syphilis, and brucellosis, but Hepatitis B (HBV) and the Human
Immunodeficiency Virus (HIV) are the two diseases specifically addressed by the OSHA Bloodborne Pathogen Standard.
While this module will focus primarily on HBV and HIV, it is important to know which bloodborne pathogens (from humans
or animals) you may be exposed to at work, especially in laboratories. For example, personnel in the College of Veterinary
Medicine might have the potential for exposure to rabies, and it would therefore be important to know specific information about
rabies.
Hepatitis B (HBV)
In the United States, approximately 300,000 people are infected with HBV annually. Of these cases, a small percentage are fatal.
"Hepatitis" means "inflammation of the liver," and, as its name implies, Hepatitis B is a virus that infects the liver. While there are
several different types of Hepatitis, Hepatitis B is transmitted primarily through "blood to blood" contact. Hepatitis B initially
causes inflammation of the liver, but it can lead to more serious conditions such as cirrhosis and liver cancer.
There is no "cure" or specific treatment for HBV, but many people who contract the disease will develop antibodies, which help
them get over the infection and protect them from getting it again. It is important to note, however, that there are different kinds of
hepatitis, so infection with HBV will not stop someone from getting another type.
The Hepatitis B virus is very durable, and it can survive in dried blood for up to seven days. For this reason, this virus is the
primary concern for employees such as housekeepers, custodians, laundry personnel and other employees who may come in
contact with blood or potentially infectious materials in a non first-aid or medical care situation.
Symptoms:
The symptoms of HBV are very much like a mild "flu". Initially there is a sense of fatigue, possible stomach pain, loss of appetite,
and even nausea. As the disease continues to develop, jaundice (a distinct yellowing of the skin and eyes), and a darkened urine
will often occur. However, people who are infected with HBV will often show no symptoms for some time. After exposure it can
take 1-9 months before symptoms become noticeable. Loss of appetite and stomach pain, for example, commonly appear within
1-3 months, but can occur as soon as 2 weeks or as long as 6-9 months after infection.
Human Immunodeficiency Virus (HIV)
AIDS, or acquired immune deficiency syndrome, is caused by a virus called the human immunodeficiency virus, or HIV. Once a
person has been infected with HIV, it may be many years before AIDS actually develops. HIV attacks the body's immune system,
weakening it so that it cannot fight other deadly diseases. AIDS is a fatal disease, and while treatment for it is improving, there is
no known cure.
Estimates on the number of people infected with HIV vary, but some estimates suggest that an average of 35,000 people are
infected every year in the US (in 2000, 45,000 new infections were reported). It is believed that as of 2000, 920,000 persons were
living with HIV/AIDS in the United States. These numbers could be higher, as many people who are infected with HIV may be
completely unaware of it.
| BLOODBORNE PATHOGENS 56
The HIV virus is very fragile and will not survive very long outside of the human body. It is primarily of concern to employees
providing first aid or medical care in situations involving fresh blood or other potentially infectious materials. It is estimated that
the chances of contracting HIV in a workplace environment are only 0.4%. However, because it is such a devastating disease, all
precautions must be taken to avoid exposure.
AIDS infection essentially occurs in three broad stages. The first stage happens when a person is actually infected with HIV.
After the initial infection, a person may show few or no signs of illness for many years. Eventually, in the second stage, an
individual may begin to suffer swollen lymph glands or other lesser diseases, which begin to take advantage of the body's
weakened immune system. The second stage is believed to eventually lead to AIDS, the third and final stage, in all cases. In this
stage, the body becomes completely unable to fight off life-threatening diseases and infections.
Symptoms:
Symptoms of HIV infection can vary, but often include weakness, fever, sore throat, nausea, headaches, diarrhea, a white coating
on the tongue, weight loss, and swollen lymph glands.
If you believe you have been exposed to HBV or HIV, especially if you have experienced any of the signs or symptoms of
these diseases, you should consult your physician or doctor as soon as possible.
Modes of Transmission
Bloodborne pathogens such as HBV and HIV can be transmitted through contact with infected human blood and other
potentially infectious body fluids such as:
•
•
•
•
•
•
•
•
•
Semen
Vaginal secretions
Cerebrospinal fluid
Synovial fluid
Pleural fluid
Peritoneal fluid
Amniotic fluid
Saliva (in dental procedures), and
Any body fluid that is visibly contaminated with blood.
It is important to know the ways exposure and transmission are most likely to occur in your particular situation, be it providing
first aid to a co-worker, handling blood samples in the laboratory, or cleaning up blood from a hallway.
HBV and HIV are most commonly transmitted through:
•
•
•
•
•
•
Sexual Contact
Sharing of hypodermic needles
From mothers to their babies at/before birth
Accidental puncture from contaminated needles, broken glass, or other sharps
Contact between broken or damaged skin and infected body fluids
Contact between mucous membranes and infected body fluids
Accidental puncture from contaminated needles and other sharps can result in transmission of bloodborne
pathogens.
In most work or laboratory situations, transmission is most likely to occur because of accidental puncture from contaminated
needles, broken glass, or other sharps; contact between broken or damaged skin and infected body fluids; or contact between
mucous membranes and infected body fluids. For example, if someone infected with HBV cut his or her finger on a piece of glass,
and then you cut yourself on the now infected piece of glass, it is possible that you could contract the disease. Anytime there is
blood-to-blood contact with infected blood or body fluids, there is a slight potential for transmission.
Unbroken skin forms an impervious barrier against bloodborne pathogens. However, infected blood can enter your system
through:
•
•
•
•
•
Open sores
Cuts
Abrasions
Acne
Any sort of damaged or broken skin such as sunburn or blisters
Bloodborne pathogens may also be transmitted through the mucous membranes of the
•
•
•
Eyes
Nose
Mouth
For example, a splash of contaminated blood to your eye, nose, or mouth could result in transmission.
PPE, Work Practices & Engineering Controls
It is extremely important to use personal protective equipment and work practice controls to protect yourself from bloodborne
pathogens.
"Universal Precautions" is the name used to describe a prevention strategy in which all blood and potentially infectious materials
are treated as if they are, in fact, infectious, regardless of the perceived status of the source individual. In other words, whether or
not you think the blood/body fluid is infected with bloodborne pathogens, you treat it as if it is. This approach is used in all
situations where exposure to blood or potentially infectious materials is possible. This also means that certain engineering and
work practice controls shall always be utilized in situations where exposure may occur.
Personal Protective Equipment
Probably the first thing to do in any situation where you may be exposed to bloodborne pathogens is to ensure you are wearing the
appropriate personal protective equipment (PPE). For example, you may have noticed that emergency medical personnel, doctors,
nurses, dentists, dental assistants, and other health care professionals always wear latex or protective gloves. This is a simple
precaution they take in order to prevent blood or potentially infectious body fluids from coming in contact with their skin.
To protect yourself, it is essential to have a barrier between you and the potentially infectious material.
Rules to follow:
•
Always wear personal protective equipment in exposure situations.
•
Remove PPE that is torn or punctured, or has lost its ability to function as a barrier to bloodborne pathogens.
•
Replace PPE that is torn or punctured.
•
Remove PPE before leaving the work area.
If you work in an area with routine exposure to blood or potentially infectious materials, the necessary PPE should be readily
accessible. Contaminated gloves, clothing, PPE, or other materials should be placed in appropriately labeled bags or containers
until it is disposed of, decontaminated, or laundered. It is important to find out where these bags or containers are located in your
area before beginning your work.
Gloves
Gloves should be made of latex, nitril, rubber, or other water impervious materials. If glove
material is thin or flimsy, double gloving can provide an additional layer of protection. Also, if
you know you have cuts or sores on your hands, you should cover these with a bandage or
similar protection as an additional precaution before donning
your gloves. You should always inspect your gloves for tears or punctures before putting them on. If a glove is
damaged, don't use it! When taking contaminated gloves off, do so carefully. Make sure you don't touch the outside
of the gloves with any bare skin, and be sure to dispose of them in a proper container so that no one else will come in
contact with them, either.
Always check your
gloves for damage
before using them
Goggles
Anytime there is a risk of splashing or vaporization of contaminated fluids, goggles and/or
other eye protection should be used to protect your eyes. Again, bloodborne pathogens can be
transmitted through the thin membranes of the eyes so it is important to protect them.
Splashing could occur while cleaning up a spill, during laboratory procedures, or while
providing first aid or medical assistance.
Face Shields
Face shields may be worn in addition to goggles to provide additional face protection. A face
shield will protect against splashes to the nose and mouth.
Aprons
Aprons may be worn to protect your clothing and to keep blood or other contaminated fluids
from soaking through to your skin.
Normal clothing that becomes contaminated with blood should be removed as soon as possible because fluids can seep through the
cloth to come into contact with skin. Contaminated laundry should be handled as little as possible, and it should be placed in an
appropriately labeled bag or container until it is decontaminated, disposed of, or laundered.
Remember to use universal precautions and treat all blood or potentially infectious body fluids as if they are
contaminated. Avoid contact whenever possible, and whenever it's not, wear personal protective equipment. If you find
yourself in a situation where you have to come in contact with blood or other body fluids and you don't have any standard personal
protective equipment handy, you can improvise. Use a towel, plastic bag, or some other barrier to help avoid direct contact.
Hygiene Practices
Handwashing is one of the most important (and easiest)
practices used to prevent transmission of bloodborne
pathogens. Hands or other exposed skin should be thoroughly
washed as soon as possible following an exposure incident.
Use soft, antibacterial soap, if possible. Avoid harsh, abrasive
soaps, as these may open fragile scabs or other sores.
Hands should also be washed immediately (or as soon as feasible) after removal of gloves or other personal protective equipment.
Because handwashing is so important, you should familiarize yourself with the location of the handwashing facilities nearest to
you. Laboratory sinks, public restrooms, janitor closets, and so forth may be used for handwashing if they are normally supplied
with soap. If you are working in an area without access to such facilities, you may use an antiseptic cleanser in conjunction with
clean cloth/paper towels or antiseptic towelettes. If these alternative methods are used, hands should be washed with soap and
running water as soon as possible.
If you are working in an area where there is reasonable likelihood of exposure, you should never:
•
Eat
•
Drink
•
Smoke
•
Apply cosmetics or lip balm
•
Handle contact lenses
No food or drink should be kept in refrigerators,
freezers, shelves, cabinets, or on counter tops where
blood or potentially infectious materials are present.
You should also try to minimize the amount of splashing, spraying, splattering, and generation of droplets when performing any
procedures involving blood or potentially infectious materials, and you should NEVER pipette or suction these materials by
mouth.
Decontamination and Sterilization
All surfaces, tools, equipment and other objects that come in contact with blood or potentially infectious materials must be
decontaminated and sterilized as soon as possible. Equipment and tools must be cleaned and decontaminated before
servicing or being put back to use.
Decontamination should be accomplished by using
•
A solution of 5.25% sodium hypochlorite (household bleach / Clorox) diluted between 1:10 and 1:100 with water. The
standard recommendation is to use at least a quarter cup of bleach per one gallon of water.
•
Lysol or some other EPA-registered tuberculocidal disinfectant. Check the label of all disinfectants to make sure they
meet this requirement.
If you are cleaning up a spill of blood, you can carefully cover the spill with paper towels or rags, then gently pour the 10%
solution of bleach over the towels or rags, and leave it for at least 10 minutes. This will help ensure that any bloodborne
pathogens are killed before you actually begin cleaning or wiping the material up. By covering the spill with paper towels or rags,
you decrease the chances of causing a splash when you pour the bleach on it.
If you are decontaminating equipment or other objects (be it scalpels, microscope slides, broken glass, saw blades, tweezers,
mechanical equipment upon which someone has been cut, first aid boxes, or whatever) you should leave the disinfectant in place
for at least 10 minutes before continuing the cleaning process.
Of course, any materials you use to clean up a spill of blood or potentially infectious materials must be decontaminated
immediately, as well. This would include mops, sponges, re-usable gloves, buckets, pails, etc.
Sharps
Far too frequently, housekeepers, custodians and others are punctured or cut by improperly disposed needles and broken glass.
This, of course, exposes them to whatever infectious material may have been on the glass or needle. For this reason, it is
especially important to handle and dispose of all sharps carefully in order to protect yourself as well as others.
Needles must be disposed of in
sharps containers.
Improperly disposed needles can
injure housekeepers, custodians,
and other people.
Needles
Needles should never be recapped.
Needles should be moved only by using a mechanical device or tool such as forceps, pliers, or broom and dustpan.
Never break or shear needles.
Needles shall be disposed of in labeled sharps containers only.
•
Sharps containers shall be closable, puncture-resistant, leak-proof on sides and bottom, and must be labeled or
color-coded.
•
When sharps containers are being moved from the area of use, the containers should be closed immediately
before removal or replacement to prevent spillage or protrusion of contents during handling or transport.
Broken Glassware
Broken glassware that has been visibly contaminated with blood must be sterilized with an approved disinfectant solution
before it is disturbed or cleaned up.
•
Glassware that has been decontaminated may be disposed of in an appropriate sharps container: i.e., closable,
puncture-resistant, leak-proof on sides and bottom, with appropriate labels. (Labels may be obtained from OSU
EHS.)
Broken glassware will not be picked up directly with the hands. Sweep or brush the material into a dustpan.
•
Uncontaminated broken glassware may be disposed of in a closable, puncture resistant container such as a
cardboard box or coffee can.
By using Universal Precautions and following these simple engineering and work
practice controls, you can protect yourself and prevent transmission of bloodborne
pathogens.
Signs, Labels & Color Coding
Warning labels need to be affixed to containers of regulated waste, refrigerators and freezers containing blood or other potentially
infectious material; and other containers used to store, transport, or ship blood or other potentially infectious materials. These
labels are fluorescent orange, red, or orange-red, and they are available from EHS. Bags used to dispose of regulated waste must
be red or orange red, and they, too, must have the biohazard symbol readily visible upon them. Regulated waste should be doublebagged to guard against the possibility of leakage if the first bag is punctured.
Labels should display this universal biohazard symbol.
Regulated waste refers to
•
Any liquid or semi-liquid blood or other potentially infectious materials
•
Contaminated items that would release blood or other potentially infectious materials in a liquid or semi-liquid state if
compressed
•
Items that are caked with dried blood or other potentially infectious materials and are capable of releasing these materials
during handling
•
Contaminated sharps
•
Pathological and microbiological wastes containing blood or other potentially infectious materials
All regulated waste must be disposed in properly labeled containers or red biohazard bags. These must be disposed at an
approved facility. Most departments or facilities that generate regulated waste will have some sort of contract with an outside
disposal company that will come pick up their waste and take it to an approved incineration/disposal facility.
Non-regulated waste (i.e., does not fit the definition of regulated waste provided above) may be disposed in regular plastic trash
bags if it has been decontaminated or autoclaved prior to disposal.
However, all bags containing such materials must be labeled, signed, and dated, verifying that the materials inside have
been decontaminated according to acceptable procedures and pose no health threat. Pre-printed labels designed for this
purpose are available from EHS, and they must be placed on the bag so that they are readily visible.
Custodians and housekeepers will not remove bags containing any form of blood (human or animal), vials containing blood,
bloody towels, rags, biohazardous waste, etc. from laboratories unless the bag has one of these labels on it. They have been given
very strict instructions not to handle any non-regulated waste unless it has been properly marked and labeled (including signature).
Custodians will not handle regulated waste.
For more information on this as it pertains to laboratories, check out the section on Treated Biomedical Waste in OSU's Lab
Safety Manual.
Emergency Procedures
In an emergency situation involving blood or potentially infectious materials, you should always use Universal Precautions and
try to minimize your exposure by wearing gloves, splash goggles, pocket mouth-to-mouth resuscitation masks, and other barrier
devices.
If you are exposed, however, you should:
1.
Wash the exposed area thoroughly with soap and running water. Use non-abrasive, antibacterial soap if possible.
If blood is splashed in the eye or mucous membrane, flush the affected area with running water for at least 15
minutes.
2.
Report the exposure to your supervisor as soon as possible.
3.
Fill out an exposure report form, if you desire. This form will be kept in your personnel file for 40 years so that you can
document workplace exposure to hazardous substances. This report is available from your supervisor or from OSU EHS.
4.
You may also go to the Human Resources to request blood testing or the Hepatitis B vaccination if you have not already
received it.
Hill PHOENIX has a specific set of procedures they will follow for all post-exposure cases. These are:
•
Document the route(s) of exposure and the
circumstances under which the exposure
incident occurred.
•
Identify and document the source individual
unless such documentation is impossible or
prohibited by law.
•
Test the source individual's blood for HBV and
HIV as soon as possible after consent is
obtained. If the source individual is known to
be seropositive for HBV or HIV, testing for that
virus need not be done.
•
Collect your blood as soon feasible, and test it
after your consent is obtained.
•
(If you consent to baseline blood collection, but do not give consent at that time for HIV serological testing, your blood
sample will be kept for at least 90 days. If, within 90 days of the incident, you decide to consent to have the baseline
sample tested, such testing shall be done as soon as possible, and at no cost to you.)
•
Administer post exposure prophylaxes, when medically indicated, as recommended by the US Public Health Service.
•
Provide counseling.
•
Evaluate reported illnesses.
Apart from the circumstances surrounding the exposure itself, all other findings or diagnosis by the SHC or health care
professional(s) will remain entirely confidential.
Hepatitis B Vaccinations
Employees who have routine exposure to bloodborne pathogens (such as doctors, nurses, first aid responders, etc) shall be offered
the Hepatitis B vaccine series at no cost to themselves unless:
•
They have previously received the vaccine series
•
Antibody testing has revealed they are immune
•
The vaccine is contraindicated for medical reasons
In these cases they need not be offered the series.
Although your employer must offer the vaccine to you, you do not have to accept that offer. You may opt to decline the
vaccination series, in which case you will be asked to sign a declination form. Even if you decline the initial offer, you may
choose to receive the series at anytime during your employment thereafter, for example, if you are exposed on the job at a
later date.
As stated in the Emergency Procedures section, if you are exposed to blood or potentially infectious materials on the job, you may
request a Hepatitis B vaccination at that time. If the vaccine is administered immediately after exposure it is extremely effective at
preventing the disease.
The Hepatitis B vaccination is given in a series of three shots. The second shot is given one month after the first, and the third
shot follows five months after the second. This series gradually builds up the body's immunity to the Hepatitis B virus.
The vaccine itself is made from yeast cultures; there is no danger of contracting the disease from getting the shots, and, once
vaccinated, a person does not need to receive the series again. There are booster shots available, however, and in some instances
these may be recommended (for example, if there is an outbreak of Hepatitis B at a particular location).
This is the end of the Bloodborne Pathogens Training Module. To receive credit for this training, take the Quiz on the
following page.
Bloodborne Pathogens Quiz
1.
If you are exposed to potentially infectious materials on the job, you may request a vaccine for which Bloodborne
disease?
a. HIV
b. Syphillis
c. Hepatitis B
d. Brucellosis
2.
Which of the following materials could contain Bloodborne pathogens?
a. Bloody saliva
b. Semen
c. Vaginal secretions
d. All of the above
3.
If you wear gloves when cleaning up an accident site, it is not necessary to wash our hands afterwards.
a. True
b. False
4.
Bloodborne pathogens may enter your system through:
a. Open cuts
b. Skin abrasions
c. Dermatitis
d. Mucous membranes
e. All of the above
5.
You should always treat all body fluids as if they are infectious and avoid direct skin contact with them.
a. True
b. False
6.
You should never eat, drink or smoke in a laboratory or other area where there may be potential exposure to Bloodborne
pathogens.
a. True
b. False
7.
If you have blood or potentially infectious materials splashed into your eye, you should flush your eye with clean, running
water for…
a. 2 minutes
b. 5 minutes
c. 10 minutes
d. 15 minutes
8.
Uncontaminated sharps may be disposed of in regular trash bags.
a. True
b. False
9.
A quarter cup of household bleach to one gallon of water provides a strong enough solution to effectively decontaminate
most surfaces, tools and equipment if left for 10 minutes.
a. True
b. False
10. Needles should never be recapped
a. True
b. False
Answers
1.
C
2.
D
3.
B
4.
E
5.
A
6.
A
7.
D
8.
B
9.
A
10.
A
LOCKOUT/TAG-OUT
THE CONTROL OF HAZARDOUS ENERGY
Recently, an employee was cleaning the unguarded side of an operating saw. The employee was caught in the moving parts of
the saw and pulled into a nip point between the saw blade and the idler wheel, resulting in fatal injuries. This accident was caused
by the failure to shut down or turn off the equipment to perform maintenance. If the employee utilized a lockout/tagout procedure,
he would still be alive today.
The Control of Hazardous Energy Source Standard (29 CFR l9lO.l47), which is more commonly known as the Lockout/Tagout
Standard, is a Federal Occupational Safety and Health Administration (OSHA) program, It is designed to prevent the unexpected
startup, or energizing, of machinery and equipment during service and maintenance operations which could cause injury to
employees. It is also designed to prevent the release of stored energy which could cause injury to employees. Industry has been
obligated to comply with the Lockout/Tagout Standard since January 3, l990.
The lockout standard applies if:
1.
The employee is required to remove or bypass a guard or other safety device during service and maintenance.
2.
An associated danger zone exists during a machine operating cycle.
3.
The employee is required to place any body part into an area of the machinery or equipment where work is actually being
performed upon the material being processed.
Minor tool changes, adjustments, and other minor service activities, which take place during normal production, are not included in
the Lockout/Tagout Standard provided they are 1) routine, repetitive, and integral to the use of the equipment, and 2) that they are
performed using alternative measures which provide effective protection for the employee.
Energy Sources
Most people immediately think of electricity as a potentially hazardous energy source. There are other sources of energy, though,
that can be just as hazardous. These energy sources include thermal, chemical, pneumatic, hydraulic, mechanical, and gravity, It
is important to remember that all sources of energy that have the potential to unexpectedly startup, energize, or release must be
identified and locked, blocked, or released before servicing or maintenance is performed.
Written Lockout/Tagout Program
In order to comply, a company must prepare a written Lockout/Tagout Program which includes the scope, purpose, authorization,
rules, and techniques to be utilized in the control of hazardous energy. Training must also be provided to all employees who are
affected by the Lockout/Tagout procedures.
The written program must have:
1.
A specific statement as to the intended use of the program.
2.
Specific steps for shutting down, isolating, and blocking machinery and equipment in order to control hazardous energy.
3.
Specific procedures for the placement and removal of lockout/tagout devices as well as the method of identifying an
individual's locks or tags.
4.
Requirements for verifying the effectiveness of the lockout/ tagout device by testing procedures for machinery and
equipment.
5.
A detailed training program for employees who perform the service and maintenance and for employees who are
indirectly affected by those operations.
6.
Descriptions of company lockout/tagout policies regarding multiple lockout/tagouts, outside personnel, shift changes, and
training of employees.
| LOCKOUT/TAG-OUT 68
Equipment
The basic equipment needed for a lockout/tagout procedure are locks and/or tags. Locks are to be utilized whenever possible.
Both locks and tags must clearly indicate the identity of the employee who applied the device. This provides positive identification
as to who is servicing the machinery and equipment. The identification will also indicate who may not have finished working in a
multiple lockout/tagout situation. The locks and tags must be durable enough to withstand the environment in which they will be
used. Information on the locks and tags must remain legible, Locks must be substantial enough to prevent removal without the
use of excessive force. Tags must be substantial enough to prevent accidental or inadvertent removal. Both locks and tags are to
be standardized by either color, shape, or size. Tags must have a standard print and format, If an energy isolating device is not
capable of being locked out, a tag is to he used. An energy isolating device is simply a mechanical device that physically prevents
the transmission or release of energy. All machinery and equipment must be designed to accept a lockout device when major
replacements, repairs,renovations,modifications of machinery or equipment are performed, or whenever new machinery is
installed.
An audit should be conducted on all machines and equipment to identify all potentially dangerous energy sources and all energy
isolating devices. By doing this,employers will be able to establish all appropriate lockout/tagout procedures.
Employee Classifications
Two types of personnel are directly affected by the Lockout/ Tagout Standard: Affected Employees and Authorized Employees.
OSHA defines an Affected Employee as an employee whose job requires him/her to operate or use machinery or equipment on
which servicing or maintenance is being performed under a lockout/tagout procedure or whose job requires him/her to work in an
area in which servicing or maintenance is being performed under a lockout/tagout procedure. OSHA defines an Authorized
Employee as an employee who implements a lockout/tagout procedure on machinery or equipment in order that servicing or
maintenance may be performed. Often, an authorized employee and an affected employee may be the same person.
Steps in a Typical Lockout/Tagout Procedure
An actual lockout/tagout procedure is simple and straightforward. There are two phases to the procedure.
Phase I - Locks, Blocks or Releases Energy:
1.
The authorized employee notifies all affected employees that a lockout/tagout procedure is ready to begin.
2.
The machinery or equipment is de-energized.
3.
The authorized employee releases or restrains all stored energy.
4.
All locks and tags are checked for defects. If any are found, the lock or tag is discarded and replaced.
5.
The authorized employee places a personalized lock or tag on the energy isolating device.
6.
The authorized employee tries stating the machinery or equipment to ensure that it has been isolated from its energy
source. The machine is then de-energized again after this test.
7.
The machinery or equipment is now ready for service or maintenance.
Phase 2 - Returns the Machinery or Equipment to Production:
1.
The authorized employee checks the machinery or equipment to be certain no tools have been left behind.
2.
All safety guards are checked to be certain that they have been replaced properly.
3.
All affected employees are notified that the machinery or equipment is about to go back into production.
4.
The authorized employee performs a secondary check of the area to ensure that no one is exposed to danger.
5.
The authorized employee removes the locks and/or tags from the energy isolating device and restores energy to the
machinery or equipment.
This basic example of the lockout/tagout procedure is used when only one person is performing service or maintenance on
machinery or equipment and when no testing or positioning of the equipment is required.
Multiple Lockout
In a multiple lockout/tagout procedure, each person working on the machinery or equipment must place a lock or tag on the
energy isolating device. If the energy isolating device will not accept multiple locks or tags, a hasp (a multiple lockout device) may
be used. The locks or tags must be placed in such a way that energy cannot be restored to the machinery or equipment until
every lock or tag is removed, As each employee involved no longer needs to maintain his/her lockout/tagout protection, that
employee removes his/her lock or tag. The employee attaching the lock or tag is the only person authorized to remove the lock or
tag.
Testing And Positioning
Before a machine can be placed in service the positioning of pats is sometimes required.
The following procedure should be followed when testing or positioning machinery or equipment during service and
maintenance:
1.
The authorized employee makes certain that the work area is clear of tools and materials.
2.
The authorized employee notifies all affected employees that the machinery or equipment will be positioned or tested.
3.
All employees leave the area
4.
Locks or tags are removed.
5.
The machine is started and tested or positioned.
6.
When testing or positioning is complete, the machinery or equipment is de-energized following the proper lockout/tagout
procedure for servicing or the machine is returned to production via the appropriate procedure.
Exemptions to Lockout / Tagout Standards
This standard covers the servicing and maintenance of machines and equipment where the unexpected energizing,startup, or
release of energy could cause injury to employees. The standard establishes minimum performance requirements for the control
of such hazardous energy,and applies to the control of energy during normal servicing /and or maintenance of machines and
equipment However, this standard does not apply to construction,agriculture and maritime employment; installation under the
exclusive control of electrical utilities; exposure to electrical hazards from work on, near, or with conductors or equipment in
electrical utilization installation; and oil and gas well drilling and servicing. Although there are exemptions to these standards this
may not eliminate your personal liability. If you have questions concerning liability obtain legal advice.
Inspections And Training
Each energy control procedure must be inspected at least annually for the purpose of
requirements of the Lockout/Tagout Standard are being met. Each inspection will be
authorized employee other than the employee who normally uses the machinery or
performs the lockout/tagout procedure. After each inspection, the employer must certify
inspection has been completed.
All employees working in an area requiring lockout/tagout procedures must
Training must include:
1.
The recognition of lockout/tagout devices and the importance of not disturbing or
removing them unless authorized.
2.
The safe application, use, and removal of energy controls,
3.
The limitations of tags in a lockout/tagout procedure.
ensuring that the
conducted by an
equipment or
that the
be trained.
Training must occur whenever there is a change in job assignment, a change in machinery or equipment, an energy control
procedure change, or a change in a process that presents a new hazard. Retraining is to be conducted whenever the employer
believes that employees' knowledge of energy control procedures is inadequate and as part of the annual inspection.
Outside Personnel
When outside personnel, such as contractors, arc on site and engaged in activities that require compliance with the
Lockout/Tagout Standard, the on-site employer and the outside employer must inform one another of their lockout/tagout
procedures. It is the responsibility of the on-site employer to ensure that his/her employees understand and comply with the
methods of the other's lockout/tagout procedures.
Shift Changes
A high percentage of accidents historically occur shortly after a shift change and are often due to a lack of communication. During
a shift change, exiting personnel should meet oncoming personnel at the lockout/tagout device. The oncoming authorized
employee should place his/her lock or tag on the energy isolating device before the exiting authorized employee removes his /her
lock or tag. If this is not possible, the oncoming authorized employee should place his/her lock or tag on the energy isolating
device immediately after the exiting authorized employee removes his/her lock or tag. Exiting employees should inform oncoming
employees of any problems or concerns regarding the service and maintenance of machinery or equipment.
Lockout/Tagout Checklist
The checklist below has been developed to assist in
complying with the Lockout/Tagout Standard:
1.
Audit all machinery and equipment for types and magnitudes of
energy and potential hazards,
2.
Identify and document all machinery and equipment for which a
lockout/tagout procedure must be developed.
3.
Identify and document, by name and by job title, all affected
employees.
4.
Identify and document, by name and by job title, all employees
authorized to perform lockout/tagout procedures.
5.
Describe and document types and locations of energy isolating
devices for all machinery and equipment identified in Step 2.
6.
Describe and document the types of energy involved and the methods to be used to dissipate or restrain the energy for
all machinery and equipment identified in Step 2.
7.
Describe and document the method established to isolate the energy (lock or tag) and any additional safety measures to
be taken.
8.
Develop a written Lockout/Tagout Program.
Summary
The Control of Hazardous Energy Source Standard requires employers to isolate machinery and equipment from its energy
sources and to lock or tag them before service or maintenance is performed. The standard also requires that all employees be
trained in the company's lockout/tagout policies and procedures.
_____1. What is OSHA’s definition of Lockout/Tag-out?
A. Making certain that all tool boxes are secure
B. The Controlling of Hazardous Energy
C. Tagging of defective product
D. Securing the Plant at the end of your shift
_____2. What types of hazardous energy must be controlled?
A. Electrical Energy
B. High Pressure Lines
C. Excessive heat in ovens or tunnels
D. All the above
_____3. When must Lockout/Tag-out be performed?
A. Whenever a guard or Safety Device is removed or bypassed
B. Whenever any associate is required to place any part of their body into an area where work is
actually being performed on material being processed
C. During service and maintenance in which unexpected energization or start or release of stored
energy could cause injury to associate
D. All the above
_____4. What is the definition of an “Authorized associate”?
A. The local area supervisor or lead person
B. An outside contractor observing the operation
C. A Hill PHOENIX Engineer
D. A person specifically trained to perform Lockout/Tag-out and install such devices
_____5. What is the definition of “Affected Personnel”?
A. Personnel working in the Shipping Department
B. All operators and helpers on a machine similar to the one being locked out
C. All personnel in the area where Lockout/Tag-out is being performed that will be affected by the
procedure and whose job requires them to work in that area or assist in the maintenance and repair
being performed
D. Done of the above
Hill PHOENIX
Lockout/Tag-out Training Certification
______________________________________________
Employee Name
(Please print)
________________
Employee #
I have received Lockout/Tag-out Training as described in the Hill PHOENIX Lockout/Tag-out Policy; in the form of
a video and booklet.
My signature indicates that I was trained on “Lock-out/Tag out.” I further certify that I understand the training that
was presented to me and I will abide and adhere to the Lockout/Tag-out Policy.
Signed: ______________________________
Date: ______________
Compressed Gas Training
This training is intended for all Hill PHOENIX employees. Throughout our Plant, compressed gas is used on a daily
basis. These gases are primarily used in the brazing torches and welders. While only qualified and authorized
personnel should use this equipment, untrained employees could unknowingly try to use it. Therefore, it is our
responsibility to advise all employees of the dangers and the safe practice of use for compressed gases.
The Six (6) Major Compressed Gases
Used at Hill PHOENIX
OXYGEN
ACETYLENE
ARGON
NITROGEN
PROPANE
REFRIGERANTS
Each gas has special handling and storage requirements that you must understand and respect. For each compressed
gas, this guide will explain the gas’s general characteristics, handling and storage requirements, and fire-fighting
procedures.
Gases Under Pressure
1. Most people believe that gas is dangerous only at high pressures. Low-pressure gas is just as lethal as highpressure gas.
2. A compressed gas cylinder under a low pressure of 10 pounds per square inch, if ruptured, has the explosive
force of five sticks of dynamite.
3. Compressed gas cylinders can explode if rough handling results in structural damage to the casing.
4. A standard gas cylinder can become a rocket and reach 34 mph in one-tenth of a second from a broken valve
connection.
Compressed Gas Handling
1. Never roll a gas cylinder on its side or rim.
2. Always use the designated cylinder hand trucks for transportation, and use the attached chain to secure the
cylinder before transporting.
3. Valve caps must remain on all cylinders, empty or full.
Protective Equipment
1. Leather work gloves are recommended when handling compressed gas cylinders.
2. Safety glasses are recommended when handling compressed gas cylinders.
Acetylene
Characteristics
1. Acetylene is extremely flammable and explosive.
2. Must remain below 15 PSI or it becomes extremely unstable and may explode.
3. Never use acetylene on any torch other than cutting torches.
| Compressed Gas Training 74
Storage Requirements
1. Always store full and empty cylinders separately in the designated storage area.
2. Acetylene must be separated by a minimum of 20 feet away from oxygen and flammable material or separated by
a wall with a fire resistance rating of one half hour.
3. Cylinders should always be stored and used in an upright position.
Handling Requirements
1.
2.
3.
4.
Use a pressure-reducing regulator set at less than 15 PSIG.
Never expose an acetylene cylinder to heat.
Always open and close cylinder valves SLOWLY. Stand on the opposite side of the regulator.
When using acetylene, close the cylinder valve before shutting off the regulator to permit the gas to bleed from
the regulator.
Exposure Symptoms
1. If the gas is present in large quantities sufficient to dilute the oxygen concentration in the air, the following
symptoms may occur: headaches, dizziness, shortness of breath, and loss of consciousness may occur.
2. There is no experimental evidence of chronic harmful effects.
First Aid
1. Acetylene is a simple asphyxiant, irritant and anesthetic.
2. First degree and minor burns should be covered in the cleanest material available. Seek immediate medical
attention.
3. Persons suffering from lack of oxygen should be moved to areas with normal atmosphere.
4. Assisted respiration should be administered if needed.
Fire Fighting (Acetylene)
1. If possible, try to stop gas flow by shutting off the valve.
2. Due to acetylene’s extremely explosive and flammable nature, immediately evacuate area of personnel and call
the fire department.
Argon & Nitrogen
Characteristics
1. Both gases are non-toxic and non-flammable.
2. In the liquid state, both argon and nitrogen will cause severe freeze burns.
3. In the liquid and gaseous state, both gases are colorless and odorless.
1.
2.
3.
4.
5.
Prevent contact of liquid argon and nitrogen with exposed skin.
Prevent entrapment of liquid in closed systems.
Always handle cylinders with care.
Use a pressure-reducing regulator when connecting to lower pressure piping systems.
Never roll, drag, or slide cylinders, even for a short distance. Always use a cylinder hand truck.
1.
2.
3.
4.
Keep cylinders away from sources of heat and direct flame.
Valve caps must remain on cylinders when not connected for use.
Avoid exposure to areas where corrosive chemicals are present.
Always separate full and empty cylinders.
Exposure Symptoms
1. Both gases are odorless and non-toxic, however, both are a simple asphyxiant.
2. Exposure to oxygen-deficient atmospheres may produce dizziness, nausea, vomiting, loss of consciousness, and
death.
3. Death may result from errors in judgment, confusion, or loss of consciousness, which prevents self-rescue.
4. Extensive tissue damage or burns may result from exposure to liquid argon or nitrogen, or cold vapors.
First Aid (Argon & Nitrogen)
1. Persons suffering from lack of oxygen should be moved to areas with normal atmospheres.
2. If the victim is not breathing, administer mouth-to-mouth.
3. If liquid or cold boil-off gas contacts a worker’s skin or eyes, frozen tissue should be flooded or soaked in tepid
water (105°-115°-F). DO NOT USE HOT WATER! Seek a physician’s care immediately.
Oxygen
Characteristics
1. Oxygen is non-toxic in most applications.
2. Oxygen is non-flammable but vigorously accelerates combustion of flammables.
3. Pure streams of oxygen will ignite petroleum products.
1.
2.
3.
4.
Prevent contact of liquid oxygen with exposed skin.
All materials used in contact with oxygen must be clean and free of petroleum products.
Some elastomers (o-rigs, valve seats, etc.,) are not compatible with oxygen.
1. Cylinders of oxygen should never be stored within 20 feet of flammable or combustible materials, especially oil
or grease.
2. Never lubricate valves or cylinders.
3. Valve caps must remain on cylinders not connected for use.
Exposure Symptoms
1. Exposure to high levels of oxygen can produce symptoms ranging from cough and chest pains to a variety of
central nervous system disorders: tingling of fingers and toes, visual and hearing disturbances, abnormal
sensations, impaired coordination, confusion, muscle twitching and seizures resembling those of epilepsy.
First-Aid
1. If liquid or cold vapor gas contacts a worker’s skin or eyes, frozen tissue should be flooded or soaked with tepid
water (105°-115°-F). DO NOT USE HOT WATER!
2. Burns resulting in blistering or deeper tissue freezing should be seen promptly by a physician.
Fire-Fighting
1. If possible, close the supply of oxygen to the fire immediately.
Propane
Characteristics
1. Extremely flammable and combustible.
2. Simple asphyxiant.
3. Only qualified personnel should refill propane containers.
1.
2.
3.
4.
5.
Use only in well-ventilated areas.
Always keep propane cylinders upright and secure.
Never expose a propane cylinder to heat.
Always open and close valves slowly.
1.
2.
3.
4.
Keep cylinders away from heat.
Do not store cylinders in heavy traffic areas.
Valve caps, where provided, should always remain on cylinders when not connected for use.
Keep propane cylinders away from storage or oxygen and other oxidizers.
Exposure Symptoms
1. Exposure symptoms may include rapid respiration, air hunger, uncoordination, fatigue, nausea, vomiting,
convulsions, loss of consciousness, and death.
2. Contact of liquid propane with skin can cause frostbite.
First-Aid
1.
2.
3.
4.
Move the affected person to an uncontaminated atmosphere.
If needed, give mouth-to-mouth. Supplemental oxygen should be administered.
Keep the victim warm and quiet. Seek medical attention promptly.
Skin-freezing. Frozen tissue should be flooded or soaked in tepid water (105°-115°-F).
WATER! Seek a physician’s care immediately.
DO NOT USE HOT
Fire-Fighting
1.
2.
3.
4.
Shut off source of propane gas.
When possible, allow fire to burn itself out to avoid the accumulation of an unburned flammable mixture.
Cool nearby cylinders with a water spray.
Keep all personnel away since containers can rupture violently when exposed to fire.
Refrigerants 22, 404A
Characteristics
1. Refrigerants are low in toxicity. However, symptoms of asphyxiation can occur at moderate levels of exposure.
2. Refrigerants are normally non-flammable.
1. Avoid breathing vapors and contact with eyes, skin or clothing.
2. Do not puncture or drop cylinders or expose them to open flame or heat.
Storage
1. Store in a well-ventilated area away from heat sources.
2. Keep cylinder caps on when not connected for use.
Exposure Symptoms
1. Drowsiness, loss of coordination, increased pulse rate, loss of consciousness.
2. Skin or eye contact may cause frostbite: immediately bathe any frostbite with lukewarm water.
Respiratory Protection Training
Why am I required to take this course?
Your workplace has been identified as having potential respiratory hazard(s) that could
result in an employee exposure. An employee exposure is an exposure to an airborne
contaminant that would occur if the employee were not using respiratory protection.
What will I learn from this course?
Respirators protect workers from respiratory hazards by preventing
exposures
to harmful airborne chemical and biological agents. However, a respirator
that is not
used properly will fail to provide adequate protection, and may even cause
certain
hazardous conditions. This training program is intended to teach you the
basic
information you need to know in order to use a respirator correctly and safely. At a later date, this online training
course will be supplemented with hands-on training using the specific respirator that is selected for you to use.
Why do I need a respirator?
This policy is driven by the company’s obligation to comply with the Occupational Safety and Health Administration
(OSHA) Respiratory Protection Standard, or 29 CFR 1910.134. A Respirator is one type of control that is usually
implemented when ventilation controls such as fume hoods are not feasible. Respirators are designed to protect the
respiratory system from inhalation of atmospheric hazards either by removing contaminants from the air before they
are inhaled or by supplying an independent source of "clean" air.
What are atmospheric hazards?
In order to answer this question, we must first review some basic properties of hazardous chemicals. There three
states in which an atmospheric hazards may exist, including:
•
Gases
•
Vapors
•
Particles
| Respiratory Protection Training 79
A gas is one of the phases of matter. Like liquids, gases are fluids: they have the ability to flow and do not resist
deformation, although they do have viscosity. Unlike liquids, however, unconstrained gases do not occupy a fixed
volume, but instead expand to fill whatever space they occupy. A vapor is the gaseous state of a substance which
under ordinary conditions exists as a liquid or solid. A particle is a very small speck of solid or liquid matter. There
are several types of air contaminants that would fall under the category of particles. These include smoke, mist, fume,
and dust. Smoke is a suspension in air of small particles resulting from incomplete combustion of a fuel. A mist is a
collection of liquid droplets suspended in air. A mist can be formed when spraying or splashing a liquid. It can also
be formed when a vapor condenses into liquid droplets in the air, as with fog. A fume is a solid particle that has
condensed from the vapor state. For instance, when metal is vaporized in welding or cutting processes, it becomes a
vapor then condenses into tiny particles, or metal fumes.
One other important atmospheric hazard is oxygen deficiency. The air we breathe normally contains 20.9% oxygen
by volume. In confined spaces or other poorly ventilated atmospheres, oxygen can become rapidly depleted. Serious
adverse health effects begin when the oxygen concentration reaches around 15%. The only type of respirator that can
be used in an oxygen deficient environment is self-contained breathing apparatus (SCBA), similar to the kind worn
by firefighters when they enter burning buildings.
Why is it important to understand the different states of atmospheric hazards?
Because the type of respirator and filtering media you select is
determined based upon the type of contaminant in your work
environment. Gases and vapors are adsorbed using activated
charcoal. Dusts, mists, and fumes are absorbed using a filtering
material. Some respirators may use a combination activated
charcoal and filtering media when particles and vapors / gases
are anticipated. The media is interchangeable and is installed
onto the facepiece of the respirator depending on the anticipated
contaminants in the work environment. As an important
reminder, an atmosphere-purifying respirator will not protect
you in an oxygen deficient environment. If the oxygen
concentration is unknown, you must have an SCBA respirator to
enter the atmosphere. SCBA respirators must also be used if the
concentration of a hazardous air contaminant is unknown, but
entry into the hazardous atmosphere must be made, as in a hazardous chemical release or other emergency. Never
presume that an entry into a hazardous atmosphere is safe!
I have allergies and I work outside where there are common allergens such as pollen and grass seed. Even
though there are technically no atmospheric hazards in my workplace, I still want to wear a respirator to
control my allergies. Does this training course apply to me?
Yes. Even though there may not be any hazardous vapors, gases, or particles in your work environment, you still need
to be aware of certain use factors and limitations of respirators. The use of a respirator by someone who doesn't
understand these limitations and use factors could lead to dangerous conditions even in the absence of atmospheric
hazards. For instance medical clearance to wear a respirator is required because there are certain medical conditions
that could cause you to be physically unable to do your job while wearing a respirator. Another potential problem
unrelated to atmospheric hazards is surface contamination. If routinely used respirators are not cleaned and
disinfected regularly, unhealthful conditions and infections could result.
What type of respirator will I need?
There are a great variety of respirator types available, and each is designed based on the specific contaminant(s)
encountered, the characteristics of the work environment, and the needs of the user. Respirators with tight-fitting
facepieces or coverings produce a protective seal around the face of the user. Air is purified when it passes through a
filtering media at the inlet cover of the facepiece. This is by far the most commonly used type of respirator.
Tight fitting coverings, or "facepieces", come primarily in two basic configurations: half-mask and full facepiece.
Half-mask respirators cover the facial area from the bridge of the nose to just below the chin. Full facepiece
respirators cover the same facial area as the half-mask, but there is also a supplemental seal around the perimeter of
the face and a protective see-through shield.
Half face respirator Full face respirator
Half-masks are the simplest form of respirator and can be used for protection against gases, vapors, or particulates.
The cartridges on the sides of the respirator contain a filtering and / or adsorbing media that removes contaminants
from the air. Thus the type of cartridge is selected based on the anticipated contaminant(s) in the work environment.
The cartridges attach to the respirator inlets, so all of the air entering the facepiece is purified before it is inhaled by
the respirator wearer. On the front of the mask is an exhalation outlet with a one way valve that allows air to leave the
facepiece.
Full facepiece respirators are used when a higher level of respiratory protection is needed, or when protection of the
eyes and face is important. Jobs that could necessitate the use of a full facepiece respirator include hazardous waste
bulking, in which there may be high atmospheric concentrations of vapors; jobs involving chemicals that are irritating
to the eyes; pesticide or herbicide spraying, where overspray may contact the eyes; or research animal care, where
allergens can affect the eyes as well as the respiratory system. Like the simpler half-face respirator, full facepieces
have interchangeable cartridges that are selected on the basis of the anticipated respiratory hazard(s).
A respirator type that is popular in the healthcare setting is the disposable filtering facepiece, or N-95. The "N"
means that the respirator is not resistant to oil, and the "95" means that the respirator is at least 95% efficient at
filtering particles of a specific size. N-95 is the minimum level of efficiency that is acceptable for protection against
hazardous particulates. Filtering facepiece respirators with greater filtration efficiency are available (e.g. N-97 and N100). An N-100 filter is also called a High Efficiency Particulate Air (HEPA) filter because it is nearly 100%
effective at filtering particles of a specific size. Filtering facepiece respirators are intended to protect against
particles, although some models may contain an activated charcoal media to control odors or vapors. However, this
type of respirator is not recommended if you have potential exposure to gases or vapors.
n100 with a HEPA
filter
I need the higher level of protection provided by a full facepiece, but my work environment is not well suited
for this type of respirator. What are my alternatives?
Full facepiece respirators are not adaptable for certain work environments. For instance, if the work environment is
hot with high humidity, then the face shield may "fog up" rapidly, causing discomfort and obstructed vision. In such
cases there are alternatives. One such alternative uses the same facepiece configuration, but utilizes a battery powered
blower motor to pull air through a purifying element, then push the air into the full facepiece. This design is called a
Powered Air Purifying Respirator (PAPR) and is particularly useful when comfort in hot, humid conditions is an
issue. Air is circulated through the facipiece producing a cooling effect that improves comfort and reduces fogging.
Additionally the blower motor does the work of pulling air through the filtering media, resulting in less physical
stress on the user. When maximum comfort and communication ability is needed, a loose-fitting covering or hood can
be used with a PAPR blower motor and air purifying element.
Powered air purifying respirator
Is there any way to determine exactly how much protection a specific respirator type will provide?
A respirator's protective capacity is rated based on Assigned Protection Factors, or APF's. The higher the
concentration of airborne contaminants, the greater the need for a high APF. APF's are numerical ratings that express
the respirators anticipated protective ability against a given contaminant. The higher the APF, the greater the
protection provided by the respirator. For instance, if the established occupational exposure limit for a particular
chemical is 10 ppm (parts of the contaminant vapor per million parts of air), a full facepiece respirator, with an APF
of 50, can safely be used in airborne concentrations of up to 500 ppm:
Occupational Exposure Limit x APF = Maximum Airborne Contaminant Concentration in which Respirator can be
Used
APF's for different classes of respirators for protection against gases / vapors are given below:
Assigned
Protection
Factor
10
Type of Respirator
Example
Any air-purifying half-mask respirator
equipped with gas / vapor cartridges
25
Any powered air-purifying respirator
with a loose-fitting hood
50
Any air-purifying full facepiece
respirator with equipped with gas /
vapor cartridges
Does OSHA require that I have knowledge of all respirator types, even
though I will only be using one certain type in performing my job?
Only to the extent that knowledge of other respirator types helps you or your
supervisor to make the correct choice regarding the best type of respirator for
your work environment. For example, if you initially select a half face respirator
and then a new contaminant is introduced to the work environment, one that
causes a need to protect the eyes and face, then a general awareness the
protective capacity and general uses of full face respirators will help you to
realize that there is a better, more protective choice in respirators for your work
environment. You may already know the exact type of respirator you will be
using or you may even know the exact manufacturer and model number. In each
case, this training program will enable you to click on internet links to obtain
information regarding the specific type, make, and model of respirator so that
you can understand exactly how the general requirements of a respiratory
protection program apply to the respirator(s) you will use.
I have asthma. Will this cause a problem when I am wearing a respirator?
Possibly. In fact, there are a number of conditions that could cause potential adverse health effects for respirator
wearers, including respiratory diseases, history of heart attack or stroke, claustrophobia, and high blood pressure to
name a few. Each of these conditions may adversely affect the health of some employees who wear respirators. A
physician or other licensed health care professional operating within the scope of his/her practice needs to medically
evaluate employees to determine under what conditions they can safely wear respirators. Thus, it is necessary to
ensure that you are physically capable of wearing a respirator.
How will I know if my respirator is fitting properly?
Fit testing must be conducted to determine proper respirator fitting. Even the
best designed and manufactured respirator will not protect the wearer if
there is an improper match between facepiece and wearer or improper
wearing practices by the user. Since there are different brands of a particular
type of facepiece available it is important to determine which one fits best. It
is also important to know how to correctly wear your respirator. Choosing
the correct respirator and knowing how to wear it are accomplished by fit
testing which is required by OSHA.
It is important to remember that no one respirator marketed will fit everyone.
Therefore, more than one brand of a given type of respirator should be
purchased to take advantage of the different characteristics of each type, and to ensure a correct fit for everyone.
Also, having more than one facepiece to choose from gives the worker a better chance of finding a respirator that is
comfortable while providing good protection.
Quantitative fit testing is the preferred method for determining proper fitting. This test is conducted using
sophisticated equipment by trained personnel. The purpose of fit testing is to detect facepiece leakage. The
quantitative test does not rely on subjective responses, and is highly sensitive and assures correct fit. This is
especially important when working in highly hazardous atmospheres which can be immediately dangerous to life or
health.
After my initial fit testing how do I know that my respirator is continuing to function correctly?
Inspection, Cleaning, Maintenance, and Storage of respirators is vital to assure that they are functioning correctly and
that they are safe to use. Meticulous respirator maintenance must be made a fundamental part of the overall respirator
program. Manufacturers' instructions for caring for your respirator should be followed to ensure correct function. It is
important to remember that poorly maintained or malfunctioning respirators do not protect the wearer and can be
more dangerous than not wearing a respirator at all. To maintain your respirator certain guidelines should be
followed. These guidelines may change due to the needs of your facility and how often you are using respirators and
for what purpose. For example in a large respirator program in which respirators are used routinely, they should be
exchanged daily for cleaning and inspection. However, in a small program involving only occasional respirator use,
this period could be weekly or monthly. It is important to evaluate your specific needs regarding respirator use to
determine the best maintenance program. General maintenance includes the following:
Inspection of your respirator:
The facepiece of a routinely used respirator should be checked before and after each use for:
•
Excessive dirt
•
Cracks, tears, holes, or distortion from improper storage
•
Inflexibility (stretch and massage to restore flexibility)
•
Cracked or badly scratched lenses in full-facepieces
•
Incorrectly mounted full-facepiece lens or broken or missing mounting clips, and
•
Cracked or broken air-purifying element holder(s), badly worn threads, or missing gasket(s) (if required).
The head straps or head harness of a routinely used respirator should be checked before and after each use for:
•
Breaks
•
Loss of elasticity
•
Broken or malfunctioning buckles and attachments, and
•
Excessively worn serrations on the head harness which might permit slippage (full facepieces only)
The air-purifying elements of a routinely used respirator should be checked before and after each use for:
•
Incorrect cartridge, canister, or filter for the hazard
•
Incorrect installation, loose connections, missing or worn gaskets, or cross-threading in holder.
•
Expired shelf-life date on cartridge or canister
•
Cracks or dents in outside case of filter, cartridge, or canister, and
•
Evidence of prior use of adsorbent cartridge or canister, indicated by absence of sealing material, tape, foil,
etc., over inlet.
OSHA states "routinely used respirators shall be collected, cleaned, and disinfected as frequently as necessary to
insure that proper protection is provided." and that emergency use respirators "shall be cleaned and disinfected after
each use." If the respirator is dirty, it should be washed with detergent in warm water using a brush. If the respirator
is not visibly soiled, it may still need to be disinfected using a solution of one part bleach to
10 parts water. Placed the respirator in the bleach solution for no less than 10 minutes, then
rinsed it thoroughly in clean water (140°F maximum) to remove all traces of detergent or
bleach. This is very important to prevent exposure that could lead to dermatitis. The use of
rubbing alcohol should be avoided because alcohols will cause the rubber components of the
facepiece to degrade. Drying of your respirator should be on a clean surface. Respirators may
also be hung to dry, but care must be taken not to damage the facepiece. Do not place the
respirator back into an airtight container or storage bag until it is completely dry, or
mold growth will result.
Cleaning of respirator
Storage of your respirator should be done in a clean, dry place free of hazards. The respirator should be able to dry
where it is stored and respirator storage must protect against:
•
Dust
•
Sunlight
•
Heat
•
Extreme cold
•
Excessive moisture, and
•
Damaging chemicals.
Clean, dry respirators should be placed in reusable plastic bags or other clean, sealable containers. They should be
stored in a clean, dry location away from direct sunlight. They should be stored in a single layer with the facepiece
and exhalation valve in a more or less normal position to prevent the rubber or plastic from taking a permanent
distorted "set".
Can I wear a respirator if I have facial hair?
No, a respirator must have a good seal around the face to ensure maximum protection. Facial hair that lies along the
sealing area of the respirator, such as beards, sideburns, moustaches, or even a few days of stubble are not permitted
when wearing a respirator. Facial hair between the wearer's skin and the sealing surfaces of the respirator will prevent
a good seal. The wearer should be cleanly shaven when wearing a respirator. The only exception would be a small
moustache that does not lie beneath the sealing surface of the respirator.
Can I wear a respirator if I wear eye glasses?
No, ordinary eye glasses should not be used with full-face respirators. Eye glasses with bars or straps that pass
through the seal of the respirator will prevent a good seal. Special corrective lenses can be mounted inside a fullfacepiece respirator and are available from all manufacturers of full-facepiece respirators. However, when wearing a
half face respirator glasses may be permitted because they do not pass through the seal.
Can I wear a respirator if I wear contact lenses?
There are several factors that limit the use of contact lenses while wearing any type of respiratory device. This is
especially true of air-supplying respirators. With full face respirators, incoming air directed toward the eye can cause
discomfort from dirt, lint, or other debris lodging between the contact lens and the pupil. It is not recommended that
contact lenses be worn while using a respirator and that other means be used such as special corrective lenses that are
mounted inside a full-facepiece respirator.
Respirator Protection Program Training
Name: ___________________________________________
Department: _______________________________________
I have been trained in and understand the following: (Put initials on line to indicate appropriate areas trained.)
Date of Training: _____________
Person Who Performed Training _______________________________
Nature of the Hazard
Engineering Controls
Why Respirator is Needed for Added Protection
Reason for Selecting Respirator Type
Method for Selecting Proper Respirator
Limitations of Selected Respirator
____________
Heat Build-up
Respiratory Problems
Medical Surveillance
____________
____________
____________
•
•
•
Methods of Putting on Respirator
Importance of Reading Manufacturer’s Instructions
Proper Wearing of Respirator
How to Adjust Prior to Fit Test
Importance of Tight Seal
Positive Pressure Test
Negative Pressure Test
Use of Supplied Air Respirator
Care of Supplied Air Respirator
Components of Supplied Air Respirator
PPE – Personal Protective Equipment
OSHA Requirements
OSHA requires employers to ensure the safety of all employees in the work
environment. Eye and face protection must be provided whenever necessary to
protect against chemical, environmental, and radiological hazards or mechanical
irritants.
Ensuring worker safety includes conducting a workplace hazard assessment and
providing adequate training for all workers who require eye and face protection.
When employees are trained to work safely, through the following requirements,
they should be able to anticipate and avoid injury from job related hazards.
o
OSHA Standards
o
Training and Qualification of Employees
o
Criteria for PPE
o
Fitting of PPE
o
Maintenance and Care of PPE
o
Contacts and Prescription (Rx) Lenses
OSHA Standards
The following OSHA standards provide mandatory requirements and compliance assistance for employers
when selecting proper eye and face protection:
o
1910.132 -General requirements
o
1910.133 -General Industry
o
1915.153 -Maritime
o
1926.102 -Construction
The employer shall ensure that each affected employee uses appropriate eye or face protection when
exposed to eye or face hazards from flying particles, molten metal, liquid chemicals, acids or caustic
liquids, chemical gases or vapors, or potentially injurious light radiation.
| PPE – Personal Protective Equipment 89
Training and Qualification of Employees
Employers must provide training for each employee who is required to use PPE in the workplace.
o
Each employee shall be trained to know at least the following:
When PPE is necessary
What PPE is necessary
How to properly don, doff, adjust, and wear PPE
Limitations of the PPE
Proper care, maintenance, useful life, and disposal of the PPE
o
All training should be conducted by a knowledgeable designated person.
o
All required training should be presented in a manner that the employee can understand.
o
Each affected employee shall demonstrate an understanding of the training specified and the ability
to use PPE properly, before being allowed to perform work requiring the use of PPE.
o
Employers who allow their employees to wear eye and face protection on a voluntary basis when not
required by OSHA or the employer must implement limited provisions of a PPE program. For all other
voluntary users, an additional written eye and face protection program that covers proper
maintenance procedures must be implemented.
Retraining
o
When the employer has reason to believe that any affected employee who has already been trained
does not have the understanding and skill required, the employer shall retrain that employee.
Circumstances where retraining is required include, but are not limited to, situations where:
Changes in the workplace render previous training obsolete
Changes in the types of PPE to be used render previous training obsolete
Inadequacies in an affected employee's knowledge or use of assigned PPE indicate that the
employee has not retained the requisite understanding or skill
Written Certification
o
The employer shall verify that each affected employee has received and understood the required
training through a written certification that contains the name of each employee trained, the date(s)
of training, and the subject of the certification.
Handling Emergencies
o
If an eye injury occurs, quick action can prevent a permanent disability. For
this reason:
Emergency eyewashes should be placed in all hazardous areas
First-aid instructions should be posted close to potential danger spots
Employees must know where the closest eyewash station is and how
to get there with restricted vision
Criteria for PPE
Eye and face protection must comply with the American National Standards Institute, ANSI Z87.1-1989
standard if purchased after July 5, 1994 or ANSI Z87.1-1968 if purchased before July 5, 1994.
[1910.133(b)(1), 1915.153(b), 1926.102(a)(2)]
o
Eye and face PPE shall be distinctly marked to facilitate identification of the manufacturer.
o
The following minimum requirements must be met by all protective devices. Protectors shall:
Provide adequate protection against the particular hazards for which they are designed
Be of safe design and construction for the work to be performed
Be reasonably comfortable when worn under the designated conditions
Fit snugly and not unduly interfere with the movements of the wearer
Be durable
Be capable of being disinfected
Be easily cleanable
Be distinctly marked to facilitate identification only of the manufacturer
Fitting of PPE
Consideration should be given to comfort and fit. Poorly fitting eye and face protection will not offer the
necessary protection.
o
Fitting of goggles and safety spectacles should be done by someone skilled in
the procedure.
Prescription safety spectacles should be fitted only by qualified optical
personnel.
o
Devices with adjustable features should be fitted on an individual basis to
provide a comfortable fit that maintains the device in the proper position.
o
Eye protection from dust and chemical splash should form a protective seal
when fitted properly.
o
Welding helmets and face shields must be properly fitted to ensure that they
will not fall off during work operations.
Maintenance and Care of PPE
Employees must be trained in the proper care, maintenance, useful life, and disposal of PPE.
Maintenance:
o
PPE must be used and maintained in a sanitary and reliable condition.
o
The use of equipment with structural or optical defects is prohibited.
o
Pitted lenses, like dirty lenses, can be a source of reduced vision. They should
be replaced. Deeply scratched or excessively potted lenses are apt to break.
o
Slack, worn-out, sweat-soaked, or twisted headbands do not hold the eye
protector in proper position. Visual inspection can determine when the
headband elasticity is reduced to a point below proper function.
Cleaning:
o
Atmospheric conditions and the restricted ventilation of the protector can cause lenses to fog.
Frequent cleansing may be necessary.
o
Eye and face protection equipment that has been previously used should be disinfected before being
issued to another employee.
o
When employees are assigned protective equipment for extended periods, the equipment should be
cleaned and disinfected regularly.
o
Several methods for disinfecting eye-protective equipment are acceptable. The most effective
method is to disassemble the goggles or spectacles and thoroughly clean all parts with soap and
warm water.
Carefully rinse all traces of soap and replace defective parts with new ones.
Swab thoroughly or completely and immerse all parts for 10 minutes in a solution of
germicidal deodorant fungicide.
Remove parts from solution and suspend in a clean place for air drying at room temperature
or with heated air.
Do not rinse after removing parts from the solution because this will remove the germicidal
residue that retains its effectiveness after drying.
Storage:
o
Goggles should be kept in a case when not in use. Spectacles, in particular, should be given the
same care as one's own glasses, since the frame, nose pads, and temples can be damaged by rough
usage.
o
Items should be placed in a clean, dust-proof container, such as a box, bag, or plastic envelope, to
protect them until reissue
Contacts and Prescription (RX) Lenses
Employers must ensure that employees who wear prescription (Rx) lenses or contacts use PPE that
incorporates the prescription or use eye protection that can be worn over prescription lenses.
o
o
Workers who wear prescription glasses must also wear required eye
protection.
Eye and face protection that fits comfortably over glasses is available.
Safety goggles and spectacles may incorporate prescription lenses.
Dust and chemicals present additional hazards to
contacts wearers. OSHA recommends that workers have an extra pair of
contacts or eyeglasses in case of contact failure or loss.
The employer shall ensure that each affected employee uses appropriate eye or face
protection when exposed to eye or face hazards from flying particles, molten metal,
liquid chemicals, acids or caustic liquids, chemical gases or vapors, or potentially
injurious light radiation.
Personal Protective Equipment (PPE) Test
(Supervisors should give this test after training the employee on the proper use and care of PPE. The supervisor
should review the test and discuss any areas requiring additional training. When the supervisor is confident that the
employee has an adequate knowledge and ability to properly use PPE associated with the job, the supervisor should
certify training.)
1. List the type(s) of PPE required for your task.
2. What are the hazards you are being protected against for each type of PPE used in your job?
3. Describe procedures for the use and care of the PPE you are using.
4. What should you look for to determine the PPE you are using is in good working order?
5. What actions do you take when your PPE becomes defective?
Certification
I have personally trained __________________________________ and answered all questions pertaining
to the proper use and care of PPE. I certify that he/she has adequate knowledge and ability to proper use
and care for the PPE associated with his/her job.
___________________________
________________
Signed
Date
I have been adequately trained on the use and care of PPE to be used by me. My supervisor has
answered all questions to my satisfaction and I understand he/she will be available for follow-up training if
needed.
___________________________
_________________
Print Name
Employee Number
___________________________
________________
Signed
Date
Machine Guarding
Crushed hands and arms, severed fingers and limbs, lacerations and abrasions - the list of possible
machinery-related injuries is long and horrifying. Many hazards are created by moving machine parts.
Safeguards are essential for protecting workers from preventable injuries.
The following standards have been established to ensure the safety of machine operators and other
employees in the area:
•
Machine Guarding
•
Point of Operation Guarding
•
Additional Guarding
•
Barrels, Containers, and Drums
•
Exposure of Blades
•
Anchoring Fixed Machinery
•
Eye and Face Protection
Machine Guarding
The purpose of machine guarding is to protect the machine operator and
other employees in the work area from hazards created by ingoing nip
points, rotating parts, flying chips & sparks. Some examples of this are
barrier guards, light curtains, two-hand operating devices etc.
General Requirements:
•
Guards must not create potential hazards and must be attached to the machine
where possible.
•
If guards cannot be attached to the machine, attach elsewhere.
| Machine Guarding 95
Point of Operation Guarding
The point of operation is the area on a
machine where work is performed.
Machines that expose an employee to
injury must be guarded. The guarding
device must:
•
Be in conformity with any
appropriate standards.
•
If specific standards are not
available, the machine
construction should prevent the
operator from having any part
of his/her body in the danger
zone during the operating
cycle.
•
Press Brake Operation
Special hand tools used for placing and removing material from point of operation
areas must allow easy handling of the material without the operator placing a hand in
the danger zone. Such tools must not replace guards required by this section.
Additional Guarding
The following is a list of machines that
usually require point of operation
guarding:
•
Guillotine cutters
•
Shears
•
Alligator shears
•
Power presses
•
Milling machines
•
Power saws
•
Jointers
•
Portable power tools
•
Forming rolls and calenders
Press Brake
Barrels, Containers, and Drums
Revolving barrels, containers, and drums must be guarded by an enclosure interlocked with
the drive mechanism, so the barrel, gun, or container cannot revolve unless the guard
enclosure is in place.
Exposure of Blades
When the periphery of the blades of a fan is
less than seven (7) feet above the floor or
working level, the blades must be guarded.
The guard must not have openings larger
than one-half (½) inch.
Running Fan
Anchoring Fixed Machinery
A machine designed for a fixed location must
be securely anchored to prevent walking or
moving.
Anchored Machine
Eye and Face Protection
•
Eye and face protection must be
provided to each employee when
exposed to eye or face hazards from
flying particles.
Safety Goggles
Falls
Working Surfaces
Falls are the leading cause of fatalities in the construction industry. An average of
362 fatal falls occurred each year from 1995 to 1999, with the trend on the
increase.
It is important that safety and health programs contain provisions to protect
workers from falls on the job. The following hazards cause the most fall-related
injuries:
Unprotected Sides, Wall Openings, and Floor Holes
Improper Scaffold Construction
Did you know?
Falls from elevation
account for one third
of all deaths
in construction.
Misuse of Portable Ladders
| Falls 98
Falls:
Unprotected Sides, Wall Openings, and Floor Holes
Am I In Danger?
Almost all sites have unprotected sides and edges, wall
openings, or floor holes at some point during construction.
If these sides and openings are not protected at your site,
injuries from falls or falling objects may result, ranging
from sprains and concussions to death.
How Do I Avoid Hazards?
•
This worker is not protected by
any of the protective systems
that are required by OSHA.
Use at least one of the following whenever
employees are exposed to a fall of 6 feet or more
above a lower level:
o
Guardrail Systems
o
Safety Net Systems
o
Personal Fall Arrest Systems
•
Cover or guard floor holes as soon as they are
created during new construction.
•
For existing structures, survey the site before
working and continually audit as work continues.
Guard or cover any openings or holes immediately.
•
Construct all floor hole covers so they will effectively
support two times the weight of employees,
equipment, and materials that may be imposed on
the cover at any one time.
•
In general, it is better to use fall prevention
systems, such as guardrails, than fall protection
systems, such as safety nets or fall arrest devices,
because they provide more positive safety means.
| Falls 99
Falls:
Improper Scaffold Construction
Am I In Danger?
Working with heavy equipment and building materials on the limited space of a scaffold is
difficult. Without fall protection or safe access, it becomes hazardous. Falls from such
improperly constructed scaffolds can result in injuries ranging from sprains to death.
•
Construct all scaffolds according to the manufacturer's instructions.
•
Install guardrail systems along all open sides and ends of platforms.
•
Use at least one of the following for scaffolds more than 10 feet above a lower
level:
o
Guardrail Systems
o
Personal Fall Arrest Systems
•
Provide safe access to scaffold platforms
•
Do not use climb cross-bracing as a means of access.
| Falls 100
Falls:
Misuse of Portable Ladders
Am I In Danger?
You risk falling if portable ladders are not safely positioned
each time they are used. While you are on a ladder, it may
move and slip from its supports. You can also lose your
balance while getting on or off an unsteady ladder. Falls
from ladders can cause injuries ranging from sprains to
death.
•
Position portable ladders so the side rails extend at
least 3 feet above the landing.
•
Secure side rails at the top to a rigid support and
use a grab device when 3 foot extension is not
possible.
•
Make sure that the weight on the ladder will not
cause it to slip off its support.
•
Before each use inspect ladders for cracked or
broken parts such as rungs, steps, side rails, feet
and locking components.
•
Do not apply more weight on the ladder than it is
designed to support
•
Use only ladders that comply with OSHA design
standards
This ladder is being used at the
proper angle, and appears to be
stable and secure.
| Falls 101
Electrical Safety
How Electricity Works
Operating an electrical switch is like turning on a water faucet. Behind the faucet (or
switch) there is a source of water (or electricity), a way to transport it, and pressure to
make it flow. The faucet's water source is a reservoir or pumping station. A pump
provides enough pressure for the water to travel through the pipes. The switch's electrical
source is a power generating station. A generator provides the pressure for the electrical
current to travel through electrical conductors, or wires.
Three factors determine the resistance of a substance to the flow of electricity.
•
What it is made of.
•
Its size.
•
Its temperature.
Substances with very little resistance to the flow of electricity are called conductors.
Examples are metals. Substances with a high resistance to the flow of electricity are
called insulators. Examples are glass, porcelain, plastic, and dry wood.
Pure water is a poor conductor of electricity, but small amounts of impurities, such as salt
and acid, make it a ready conductor. Perspiration contains both water, salts, and
impurities. When the skin is dry, it is a poor conductor of electrical current. When it is
moist, it readily conducts electricity. Use extreme caution when working with electricity
where there is water in the environment or on the skin. This concept applies to other
items such as wood. When wood is dry it is a poor conductor, when wet wood conducts
electricity more readily.
| Electrical Safety 102
How Shocks Occur
Electricity travels in closed circuits, normally through a conductor. Shock results when the body becomes
part of the electrical circuit; current enters the body at one point and leaves at another. Typically, shock
occurs when a person contacts:
Both wires of an energized
circuit.
One wire of an energized
circuit and the ground.
A metallic part in contact with
an energized wire while the
person is also in contact with
the ground.
Metallic parts of electric tools and machines can become energized if there is a break in the insulation of
their wiring. A low-resistance wire between the metallic case of the tool/machine and the ground – an
equipment grounding conductor – provides a path for the unwanted current to pass directly to the ground.
This greatly reduces the amount of current passing through the body of the person in contact with the tool
or machine. Properly installed, the grounding conductor provides protection from electric shock.
How Electrical Current Affects the Human Body
Three primary factors affect the severity of the shock a person
receives when he or she is a part of an electrical circuit:
•
Amount of current flowing through the body (measured in
amperes).
•
Path of the current through the body.
•
Length of time the body is in the circuit.
Other factors that may affect the severity of the shock are:
•
•
The voltage of the current.
•
The presence of moisture in the environment.
•
The phase of the heart cycle when the shock occurs.
The general health of the person prior to the shock.
Effects can range from a barely perceptible tingle to severe burns and immediate cardiac
arrest. Although it is not known the exact injuries that result from any given amperage, the
following table demonstrates this general relationship for a 60-cycle, hand-to-foot shock of
one second's duration:
Current level
(in milliamperes)
Probable effect on human body
1 mA
Perception level. Slight tingling sensation. Still dangerous under certain
conditions.
5 mA
Slight shock felt; not painful but disturbing. Average individual can let
go. However, strong involuntary reactions to shocks in this range may
lead to injuries.
6-30 mA
Painful shock, muscular control is lost. This is called the freezing
current or "let-go" range.
50-150 mA
Extreme pain, respiratory arrest, severe muscular contractions.
Individual cannot let go. Death is possible.
1000-4300 mA
10,000 mA
Ventricular fibrillation (the rhythmic pumping action of the heart
ceases.) Muscular contraction and nerve damage occur. Death is most
likely.
Cardiac arrest, severe burns and probable death.
Wet conditions are common during low-voltage electrocutions. Under dry conditions,
human skin is very resistant. Wet skin dramatically drops the body's resistance.
Dry Conditions: Current = Volts/Ohms = 120/100,000 = 1mA
a barely perceptible level of current
Wet conditions: Current = Volts/Ohms = 120/1,000 = 120mA
sufficient current to cause ventricular fibrillation
If the extensor muscles are excited by the shock, the person may be thrown away from
the circuit. Often, this can result in a fall from elevation that kills a victim even when
electrocution does not.
When muscular contraction caused by stimulation does not allow the victim to free himself
from the circuit, even relatively low voltages can be extremely dangerous, because the
degree of injury increases with the length of time the body is in the circuit. LOW VOLTAGE
DOES NOT IMPLY LOW HAZARD!
100mA for 3 seconds = 900mA for .03 seconds
in causing fibrillation
Note that a difference of less than 100 milliamperes exists between a current that is barely
perceptible and one that can kill.
High voltage electrical energy greatly reduces the body's resistance by quickly breaking
down human skin. Once the skin is punctured, the lowered resistance results in massive
current flow.
Ohm's law is used to demonstrate the action.
At 1,000 volts, Current = Volts/Ohms = 1,000/500 = 2 Amps
which can cause cardiac standstill and serious damage to internal organs.
Photo Examples of Burns and Other Injuries
Electrical Burns
•
Entrance Wound: High
resistance of skin transforms
electrical energy into heat,
which produces burns around
the entrance point (dark spot
in center of wound). This man
was lucky, the current
narrowly missed his spinal
cord.
•
Exit Wound: Current flows
through the body from the
entrance point, until finally
exiting where the body is
closest to the ground. This
foot suffered massive internal
injuries, which weren't readily
visible, and had to be
amputated a few days later.
Arc or Flash Burns
•
This man was near a power
box when an electrical
explosion occurred. Though
he did not touch the box,
electricity arced through the
air and entered his body. The
current was drawn to his
armpits because perspiration
is very conductive.
Thermal Contact Burns
•
Current exited this man at his
knees, catching his clothing
on fire and burning his upper
leg.
Internal Injuries
•
This worker was shocked by a
tool he was holding. The
entrance wound and thermal
burns from the overheated
tool are apparent
•
Same hand a few days later,
when massive subcutaneous
tissue damage had caused
severe swelling (swelling
usually peaks 24-72 hours
after electrical shock). To
relieve pressure which would
have damaged nerves and
blood vessels, the skin on the
arm was cut open.
Involuntary Muscle Contraction
•
This worker fell and grabbed a
powerline to catch himself.
The resulting electric shock
mummified his first two
fingers, which had to be
removed. The acute angle of
the wrist was caused by
burning of the tendons, which
contracted, drawing the hand
with them.
Ladder Safety
The OSHA Standard for portable ladders contains specific requirements designed to ensure
worker safety:
•
Loads
•
Angle
•
Rungs
•
Slipping
•
Other Requirements
Loads
•
Self-supporting (foldout) and non-self-supporting (leaning) portable ladders
must be able to support at least four times the maximum intended load, except
extra-heavy-duty metal or plastic ladders, which must be able to sustain 3.3
times the maximum intended load. (See Figure 1.)
Angle
•
•
Non-self-supporting ladders, which must lean against a wall or other support,
are to be positioned at such an angle that the horizontal distance from the top
support to the foot of the ladder is about 1/4 the working length of the ladder.
(See Figure 2.)
Figure 1
In the case of job-made wooden ladders, that angle should equal about 1/8 the
working length. This minimizes the strain of the load on ladder joints that may
not be as strong as on commercially manufactured ladders.
Rungs
•
Ladder rungs, cleats, or steps must be parallel, level, and uniformly spaced
when the ladder is in position for use. Rungs must be spaced between 10 and
14 inches apart.
•
For extension trestle ladders, the spacing must be 8-18 inches for the base,
and 6-12 inches on the extension section.
•
Rungs must be so shaped that an employee's foot cannot slide off, and must be
skid-resistant. (See Figure 3.)
Slipping
•
Ladders are to be kept free of oil, grease, wet paint, and other slipping
hazards.
•
Wood ladders must not be coated with any opaque covering, except
identification or warning labels on one face only of a side rail.
Figure 2
Figure 3
| Ladder Safety 107
Other Requirements
•
Foldout or stepladders must have a metal spreader or locking device to hold
the front and back sections in an open position when in use. (See Figure 4.)
•
When two or more ladders are used to reach a work area, they must be offset
with a landing or platform between the ladders.
•
The area around the top and bottom of ladder must be kept clear.
•
Ladders must not be tied or fastened together to provide longer sections,
unless they are specifically designed for such use. (See Figure 5.)
•
Never use a ladder for any purpose other than the one for which it was
designed.
Figure 4
Figure 5
Additional Examples
This is improperly using the
top rung of this step ladder to
work from.
| Ladder Safety 108
Hearing Conservation Training
Noise is usually defined as unwanted sound. The following sections provide
information related to the origins of noise and its impact on our ability to hear:
•
Physics of Sound
•
Anatomy and Physiology of the Ear
•
Effects of Excessive Exposure
•
Ultrasonics
Physics of Sound
TOP
Sound is the physical phenomenon that stimulates our sense of hearing. It is an
acoustic wave that results when a vibrating source, such as machinery, disturbs an
elastic medium, such as air.
•
In air, sound is usually described as variations of pressure above and below
atmospheric pressure. These fluctuations, commonly called sound pressure,
develop when a vibrating surface forms areas of high and low pressure,
which transmit from the source as sound.
Anatomy and Physiology of the Ear
TOP
The ear is the organ that makes hearing possible.
It can be divided into three sections:
•
External outer ear
•
Air-filled middle ear
•
Fluid-filled inner ear
The function of the ear is to gather, transmit, and
perceive sounds from the environment.
This involves three stages:
1. Modification of the acoustic wave by the
outer ear, which receives the wave and
directs it to the eardrum.
2. Conversion and amplification of the modified acoustic wave to a vibration of the eardrum
(transmitted through the middle ear to the inner ear).
3. Transformation of the mechanical movement of the wave into nerve impulses that will travel to
the brain, which then perceives and interprets the impulse as sound.
| Hearing Conservation Training 109
Effects of Excessive Exposure
Although noise-induced hearing loss is one of the most common occupational illnesses, it is often
ignored because there are no visible effects, it usually develops over a long period of time, and, except
in very rare cases, there is no pain. What does occur is a progressive loss of communication,
socialization, and responsiveness to the environment. In its early stages (when hearing loss is above
2,000 Hertz (Hz)) it affects the ability to understand or discriminate speech. As it progresses to the
lower frequencies, it begins to affect the ability to hear sounds in general.
The three main types of hearing loss are conductive , sensorineural or a combination of the two.
The effects of noise can be simplified into three general categories:
•
Primary Effects, which includes noise-induced temporary threshold shift, noise-induced
permanent threshold shift, acoustic trauma, and tinnitus.
•
Effects on Communication and Performance, which may include isolation, annoyance, difficulty
concentrating, absenteeism, and accidents.
•
Other Effects, which may include stress, muscle tension, ulcers, increased blood pressure, and
hypertension.
In some cases, the effects of hearing loss may be classified by cause.
Ultrasonics
TOP
Ultrasound is high-frequency sound that is inaudible, or cannot be heard, by the human ear. However,
it may still affect hearing and produce other health effects.
Factors to consider regarding ultrasonics include:
•
•
The upper frequency of audibility of the human ear is approximately 15-20 kilo-Hertz (kHz).
This is not a set limit and some individuals may have higher or lower (usually lower)
limits.
The frequency limit normally declines with age.
Most of the audible noise associated with ultrasonic sources, such as ultrasonic welders or
ultrasonic cleaners, consists of subharmonics of the machine's major ultrasonic frequencies.
Example: Many ultrasonic welders have a fundamental operating frequency of 20 kHz,
a sound that is at the upper frequency of audibility of the human ear. However, a good
deal of noise may be present at 10 kHz, the first subharmonic frequency of the 20 kHz
operating frequency, and is therefore audible to most persons.
Hearing Protection Devices (HPDs)
Hearing protection devices (HPDs) are considered the last option to control
exposures to noise. HPDs are generally used during the necessary time it takes
to implement engineering or administrative controls, or when such controls are
not feasible.
Basic Requirements
•
Employers must make HPDs available to all employees exposed at or above the action level.
These must be provided at no cost to employees and must be replaced as necessary.
•
Employers must ensure that HPDs are worn by employees:
where feasible administrative and engineering controls fail to reduce sound levels within
those listed in or who are
exposed at or above the action level and who
o
have not yet had a baseline audiogram established or
o
have experienced a standard threshold shift (STS).
HPD Selection and Use
•
Employees must be given the opportunity to select their HPDs from a suitable variety.
Generally, this should include a minimum of two devices, representative of at least two
different types.
•
The employer must provide training in the use and care of all HPDs provided to employees.
•
The employer must ensure proper initial fitting of HPDs and supervise their correct use.
HPD Attenuation
•
Attenuation refers to the damping or decrease of noise levels as a result of wearing HPDs.
•
The employer must evaluate HPD attenuation for the specific noise environments in which the
HPD will be used.
•
HPDs must attenuate employee exposure to at least an eight hour time-weighted average of 90
dBA.
•
For employees who have experienced a standard threshold shift (STS), HPDs must
attenuate exposure at or below the action level of 85 dBA-TWA (time-weighted
average).
The adequacy of the HPDs must be re-evaluated whenever employee noise exposures increase
to the extent that they may no longer provide adequate attenuation. The employer must
provide more effective hearing protectors as necessary.
Violence in the Workplace
The National Institute for Occupational Safety and Health (NIOSH) has found that an average of 20 workers are
murdered each week in the United States. In addition, an estimated 1 million workers -18,000 per week - are victims
of nonfatal workplace assaults each year.
Homicide is the second leading cause of death on the job, second only to motor vehicle crashes. Homicide is the
leading cause of workplace death among females. However, men are at three times higher risk of becoming victims of
workplace homicides than women. Homicide is also the leading cause of death for workers under 18 years of age.
The majority of workplace homicides are robbery related crimes (71%) with only 9% committed by coworkers or
former coworkers. Additionally, 76% of all workplace homicides are committed with a firearm.
Most nonfatal workplace assaults occur in service settings such as hospitals, nursing homes, and social service
agencies. Forty eight percent of nonfatal assaults in the workplace are committed by a health care patient. Nonfatal
workplace assaults result in more than 876,000 lost workdays and $16 million in lost wages. Nonfatal assaults occur
among men and women at an almost equal rates.
The circumstances of workplace violence differ significantly from those of other types of homicides. While most
workplace homicides are robbery-related, less than 10% of homicides in the general population occur during a
robbery. Additionally, in the general population about 50% of all murder victims were related to their assailants
whereas the majority of workplace homicides are believed to occur among people who do not know each other. These
differences call for unique prevention measures targeted specifically to the workplace.
Risk Factors
Factors that place workers at risk for violence in the workplace include interacting with the public, exchanging
money, delivering services or goods, working late at night or during early morning hours, working alone, guarding
valuable goods or property, and dealing with violent people or volatile situations.
Anyone can become the victim of a workplace assault, but the risks are much greater in certain industries and
occupations. For workplace homicides, the taxicab industry has the highest risk at 41.4/100,000, nearly 60 times the
national average rate (0.70/100,000). The taxicab industry is followed by liquor stores (7.5) detective/protective
services (7.0), gas service stations (4.8) and jewelry stores (4.7). The occupations with the highest homicide rates are
taxicab drivers/chauffeurs (22.7), sheriffs/bailiffs (10.7), police and detectives public service (6.1), gas station/garage
workers (5.9), and security guards (5.5). The majority of nonfatal assaults occurred in the service (64%) and retail
trade (21%) industries. Specifically, 27% occurred in nursing homes, 13% in social services, 11% in hospitals, 6% in
grocery stores, and another 5% occurred in eating and drinking places.
Prevention
A number of environmental, administrative, and behavioral strategies have the potential for reducing the risk of
workplace violence. Examples of prevention strategies include (but are not limited to) good visibility within and
outside the workplace, cash handling policies, physical separation of workers from customers or clients, good
lighting, security devices, escort services, and employee training. No single strategy is appropriate for all workplaces,
but all workers and employers should assess the risk of violence in their workplaces and take appropriate action to
reduce those risks. A workplace violence prevention program should include a system for documenting incidents,
procedures to be taken in the event of incidents, and open communication between employers and workers.
| Violence in the Workplace 112
Forklift Safety and Training
The usefulness of the Motorized Vehicle is directly related to the all-around efficiency of the operator. It is essential
that the operators of such equipment be physically fit, mentally alert and thoroughly trained.
Driver training must start with the person at the wheel; however, it also requires the complete cooperation of
everyone concerned to make the program effective. This cooperation must originate with management and convey
through all departments involved in the use and maintenance of material handling equipment to include powered
industrial trucks.
Hill PHOENIX will comply with OSHA guidelines and use the appropriate Powered Industrial Truck per situation.
Hill PHOENIX has no known hazards that would inhibit the use of any Powered Industrial Truck listed in the
designations.
Hill PHOENIX will use an approved 4-hours course to train employees to drive a Powered Industrial Truck.
Employees assigned to drive a Powered Industrial Truck must be certified and re-certified every 3 years or in the
event of an accident.
Goals
To develop highly trained and skillful operators to reduce losses and injuries from accidents, downtime, material
damage and added maintenance.
The following program will be followed without exception when a person is assigned to drive a Motorized Vehicle.
Only trained and authorized drivers will be allowed to operate any Motorized Vehicle.
| Forklift Safety and Training 113
Use of the following form:
The operator completes the left side of the form indicating whether safety items are good or defective. If no defects
are noted, the operator initials on the bottom line and deposits the form in a box provided for the purpose. If a defect
is noted, the operator reports it to his/her supervisor with his/her portion filled out. The supervisor then evaluates the
safety problem and either authorizes the truck to be used if the item is of a minor nature and the supervisor can
schedule a repair, or he takes the truck “out of service”. If the conditions warrant, the supervisor will write “out of
service” in the instruction section on the right hand side of the form and then the truck can only be driven to the
repair shop for immediate repairs.
The technician will complete the repair and indicate what was required on the form. Then he will initial and date the
form.
The operator will make his/her usual pre-use check and if found O.K.; he will initial the form and return it to the
technician who will file the form. The operator can then put the truck back into service.
Operator Name:_______________________________
Employee #: _________
Date: ______________
Time of Inspection: ______________
Forklift #: __________
Daily Forklift Inspection Sheet
A daily inspection sheet must be completed prior to operation AND start of each 8 hour shift.
Inspection Items
Tires
Inspect for foreign particles, gouges, and
cuts in the tire.
OK
Not OK
Overhead Guard
Inspect for damage and cracks; check for loose
or missing bolts.
OK
Not OK
Mast & Carriage
Inspect for loose or missing bolts, wear/damage. (DO NOT
put hands on inside of carriage!)
OK
Not OK
Backrest
Inspect for loose or missing bolts.
OK
Not OK
OK
Not OK
Safety Equipment
Inspect for operation of lights, alarms,
and fire extinguisher gauges.
OK
Not OK
Service Brakes
Inspect pedal, operation of brake and ensure it
is functioning smoothly.
OK
Not OK
Steering
Inspect to ensure functioning smoothly.
OK
Not OK
Drive Control
Inspect to ensure functioning smoothly, both
forward and reverse.
OK
Not OK
Hoist and Lowering Control
OK
Not OK
Tilt Control
OK
Not OK
Operators Compartments
Inspect seat belts, seat adjustments, and horn
operation.
Forklift checks out – everything in compliance.
TAKE OUT OF SERVICE. Maintenance needed.
________________________________
Signed
Hand Trucks
Safe Operating Procedure
1. Hand trucks going down inclines or ramps should always be ahead of the trucker.
2. When loading trucks, truckers should keep their feet clear of wheels. Loads should be placed so they will not tip,
shift or fall off. Overloading creates a hazard to both truckers and other employees.
3. Tongues or handles of flat body trucks should be provided with counter weights, springs, or hooks to hold them
vertical when not in use. Truckers should be instructed to leave the handles in such a position so that it will
never be a tripping hazard.
4. Trucks should not be parked in aisle ways or other places where they may obstruct traffic or constitute a
stumbling hazard.
5. Extra caution should be observed at blind corners and/or cross aisles.
6. The trucker should observe safe lifting practices while loading and unloading his/her truck.
Be alert at all times; never engage in horseplay and obey traffic rules!
Forklift Operation & Safety Test
Name: _______________________________
Date:_____________
Employee #_________________
BUM:_________________
__________1. (True/False) In order to solve an “Inch Pound Equation”, you must use information provided
on a truck’s data plate.
__________2. (True/False) All industrial truck (lift trucks) are equipped with a clutch.
__________3. Before loading or unloading a trailer at a loading dock, you should:
A.
B.
C.
D.
Inspect the floor of the trailer to ensure it will support the lift truck and the load.
Chock the wheels of the trailer.
Make sure the dock plates, boards, and ramps are in place and secure.
All of the above.
__________4. (True/False) A brake pedal that sinks in the floor under continued pressure is in good
operating condition.
__________5. The front wheels of a lift truck serve as the ______________ between the weight of the truck
and the weight of the load being carried.
A.
B.
C.
D.
Balance Point
Fulcrum Pont
Center of Gravity
Seesaw Center
__________6. The most important safety devise on your lift truck is:
A.
B.
C.
D.
E.
Horn
Seat Belt
Warning Light
Backup Alarm
You
__________7. (True/False) It is safe to give someone a ride on your lift truck.
__________8. (True/False) Always check the air pressure in tires from the side, not by facing they tread.
__________9. (True/False) You can place your hand and feet outside of the operator’s compartment, as long
as your head and body are protected.
__________10. What is wrong with this illustration?
A. Driving in the wrong direction.
B. Load is too high.
C. Nothing
__________11. Which of the following should NOT be allowed during the refueling or recharging process?
A.
B.
C.
D.
Park your lift truck in a designated refueling/recharging area.
Do not block doorways or access to production or emergency equipment.
Keep a flame burning nearby to burn off unwanted vapors or gases.
Check to see that there is a fire extinguisher nearby.
__________12. (True/False) The load capacity of a truck can be found on its data plate.
__________13. (True/False) You can stand under the forks, if the engine of the lift truck is turned off.
__________14. If your trucks starts to tip over:
A.
B.
C.
D.
E.
Don’t jump.
Stay in your seat.
Grip the wheel securely.
Brace yourself with your feet.
All of the above.
__________15. (True/False) Rear wheel steering is used on lift trucks because it gives the operator greater
control when using the forks.
__________16. What type of gauge is this?
A.
B.
C.
D.
E.
Gas Gauge
Amperes Gauge
Oil Gauge
Total Hour Meter
None of the above
__________17. When parking or leaving your truck, you should:
A.
B.
C.
D.
E.
Park or leave your truck in a safe area away from traffic.
Lower the forks until they are flat on the floor.
Turn off the engine.
Set the parking brake and set the directional control to neutral.
All of the above
__________18. (True/False) Anyone who has a valid driver’s license can operate a lift truck.
__________19. (True/False) You can drive a lift truck over any type of surface.
__________20. (True/False) The three major parts of a lift truck are the body (truck), overhead guard, and
hydraulic lift.
__________21. (True/False) It is part of your job to complete a Daily Operator’s Report after you have
thoroughly inspected your lift truck.
__________22. Which of the load position in the below illustration is the most stable?
A. 1
B. 2
C. 3
__________23. (True/False) If the lift mechanism on your lift fails, you should try to repair the chains or
hydraulic system yourself.
__________24. (True/False) All industrial trucks (lift trucks) are equipped with controls which allow you to
raise/lower and tilt the forks.
__________25. (True/False) Wide and long loads are more unstable than other type of loads.
__________26. Which of the following is NOT a type of lift truck?
A.
B.
C.
D.
Gasoline Powered
Diesel Powered
Air-Cooled Powered
Electric Powered
__________27. (True/False) Lift trucks use a hydraulic cylinder attached to chains to raise and lower the
forks.
__________28. (True/False) When transporting a load, you should not raise your load more than 8” from the
ground.

Safety Regulations And Training Manual

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