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Environment Health and Safety (EHS) Services, Industrial Hygiene, Occupational Health and Safety, Respiratory Service Solutions

Silica Dust Exposure During Fracking

By John Baker, Total Safety Certified Industrial Hygienist

The public debate about hydraulic fracturing, or “fracking,” has weighed the potential for environmental pollution versus the economic and energy independence benefits which fracking has unlocked. But recently, worker exposure to silica dust during fracking has been highlighted by the National Institute for Occupational Safety and Health (NIOSH).

One commonly used method of fracking requires large volumes of sand and water to be pumped into wells at high pressures to break up tight formations, like shale, which have trapped oil and gas. Many truckloads of sand are off loaded and transferred by conveyor belts before being mixed with water and other chemicals and pumped downhole. The dust produced, which may contain up to 99% crystalline silica, is a health concern due to the risk of silicosis, a progressive and disabling lung disease.

Several oil and gas companies partnered with NIOSH in the collection of 116 personal air samples at 11 fracking sites in five states. Almost half of the air samples exceeded the enforceable OSHA Permissible Exposure Limit (PEL), which is defined on a sliding scale depending on the amount of silica in the respirable fraction of dust collected. NIOSH has established a recommended silica exposure limit (REL) of 0.05 mg/m3. Almost 80% of the samples exceeded this REL.

Until a safe and economically viable substitute can be found or engineering controls such as exhaust ventilation are installed, personal protective equipment including respirators must be used. A NIOSH approved, properly fitted and worn half mask or filtering facepiece dust respirator provides protection only up to 10 times the relevant occupational exposure limit. Almost 10% of the samples were at least 10 times the OSHA PEL and 30% of the samples were at least 10 times the NIOSH REL. Dust respirators alone may not adequately protect workers from the risk of silicosis during fracking.  An OSHA NIOSH hazard alert may be downloaded at http://www.osha.gov/dts/hazardalerts/hydraulic_frac_hazard_alert.pdf  . This excellent document provides detailed information about the study and links to additional information.

Industry and government are continuing to cooperate on finding workable controls. Rick Ingram, S.G.E, BP North America Gas, and the Chairperson of the National STEPS network states that:

NIOSH, OSHA and the US Onshore E&P Industry have been working in a cooperative effort to ensure that we fully understand this issue and protect our workers. As part of this effort, a focus group has been formed to further explore respirable silica, share best practices and develop a unified plan forward. Our industry has much to be proud of. We have the privilege of helping to supply low cost domestic energy to our nation while providing high quality, good paying jobs. Through the efforts of industry associations, organizations and agencies such as API, AESC, IADC, IPAA, SafeLandUSA, National STEPS Network, NIOSH, OSHA, educational institutions and countless dedicated individuals and professionals, we are we are working diligently to make our industry segment the safest of all industries. The fact that this hazard was identified and is being mitigated though voluntary, cooperative efforts demonstrates how far we have progressed and the very positive future of health and safety in US Onshore Exploration and Production segment.  To learn more, visit www.nationalstepsnetwork.com.

To learn more about potential respiratory hazards during fracking, call us at 888.44.TOTAL.

Occupational Health and Safety, Turnaround Support Service Solutions, Uncategorized

Hazard Recognition for Turnarounds

By John Baker, Total Safety Certified Industrial Hygienist

These are the “Top Ten” most frequently cited OSHA standards for the past year:

  1. Scaffolding
  2. Fall Protection
  3. Hazard Communication
  4. Respiratory Protection
  5. Lock Out/Tag Out
  6. Electrical, wiring
  7. Powered Industrial Trucks
  8. Ladders
  9. Electrical, general
  10. Machine Guarding

Let’s take this list of OSHA standards and translate it into the actual hazards and how to recognize them in the workplace to prevent accidents and ensure compliance. What should you look for to prevent the top ten OSHA citations during turnarounds?

Scaffolding is the most frequently cited standard, followed by fall protection. We must be sure that each scaffold has a current, daily inspection tag, proper handrails and toe boards, and is erected on a level, firm surface. If a scaffold is more than four times taller than it is wide, is it secured to keep it from tipping over? Fall protection for construction is required for working six feet or more above ground level. Are your anchor points strong enough? They must hold 5,000 pounds for each person attached to them. Are your harnesses inspected prior to every use to be sure that they are free of defects? Where are floor and wall openings – are they guarded? Where are holes that tools, parts, aerosol cans or hot material could fall through? Are they covered and marked?

Do you have all the Material Safety Data Sheets for the welding rods, paints, adhesives, abrasive media, catalysts, and are they reviewed in everyday language by the supervisor before the craft people use them? Are containers labeled with the name of the contents and all warnings?

Has a lock out/tag out system been set up for each area where energy must be neutralized to allow safe work? Are there alternative pathways for electrical, hydraulic, pneumatic or any other sort of “stored energy” to activate equipment?  Can you confirm that all these alternative energy sources been locked out?

Electrical wiring must be inspected to be sure it is free of nicks, kinks, frayed insulation and that the plugs ensure a good ground connection. OSHA requires 3 wire cord sets, not “ribbon” 2 wire cords. Excessive use of cords should be avoided and temporary wiring should be securely fastened every 10 feet and protected from physical damage. Are conduit fittings and junction box covers securely attached and breaker boxes and panel covers closed? Are there enough ground fault circuit interrupters available and have they been tested to make sure that they will work when needed. Are electrical outlets overloaded? Never force a circuit breaker to stay on as this could over draw an electrical device and cause a fire.  OSHA considers 600 volts or more as “high voltage”: make sure that any exposed live parts are guarded and posted with warning signs forbidding unqualified personnel entry or access. Assume that all overhead power lines are energized and keep at least 10 feet away from them.

Have all the appropriate people had forklift driving training? Are inspections done before each work shift when the forklifts or other industrial trucks are used? No one should be riding on the forks or anywhere else other than in a seat with a proper seat belt.

Are ladders inspected to be sure that rungs and steps are free from grease or oil, and joints between steps/rungs and side rails are tight? Are all hardware and fittings securely attached? A portable ladder should be angles so that its base is one-fourth of its working length from the vertical and at least 3 feet should project over the landing to be accessed.  Ladders must not be placed in boxes, barrels or other unstable bases to get additional height. No one should be standing on the top step of a step ladder. A rope should be used to raise or lower loads. Nothing should be carried in the hands while climbing a ladder.

Machine guarding in the shops is as important as the more visible hazards in the process units. Have existing guards been modified or removed? Rotating shafts and tools; saw blades, grinders, and other equipment with unprotected points of operation should have guards, interlocks or some means of keeping hands and body parts out of danger.

These are just a few of the most common hazards to look for related to the top 10 OSHA citations.  See how many more you can find at your job site. These tips are just the tip of the iceberg!

For more information about occupational hazards, feel free to contact us at 888.44.TOTAL.

Occupational Health and Safety

Total Safety’s Valero-Texas City Location Awarded OSHA’s VPP Star Certification for Safety Excellence

Total Safety's Valero-Texas City Location Receives OSHA VPP Star CertificationTotal Safety, a leading global safety services company, announced that its Valero-Texas City location has been awarded the Occupational Safety and Health Administration’s (“OSHA”) prestigious Voluntary Protection Program (“VPP”) Star Certification for safety excellence in the workplace. This is the fifth such award for Total Safety.

OSHA’s VPP recognizes employers and workers in the private industry and federal agencies who have implemented effective safety and health management systems and maintained injury and illness rates below national Bureau of Labor Statistics averages for their respective industries. VPP Star certification recognizes the outstanding efforts of employees and managers who have achieved exemplary safety and health management systems (SHMS). Safety is a core value throughout the Total Safety organization and is practiced each and every day at all facilities.

“The OSHA VPP star certification is truly an honor. This recognition demonstrates the commitment of our staff to both their own safety and the safety of others,” said Chuck Gibson, Total Safety’s VPP Director. “They should be congratulated for their attention to workplace safety.”

With more than 20 other sites currently in the review process, Total Safety strives for Star Certification at additional locations within the next few years.

Ellis Pellerin, Total Safety’s Health, Safety & Environment (HSE) Director, added, “Outstanding teamwork leads to safety success, and the Total Safety team is dedicated to be the very best.”

In addition to the OSHA honor, Total Safety has received the “Best in Class” award from the Houston Business Roundtable, AFPM Awards, and a host of industry and customer safety accolades.

Safety Training & Consulting Services

The Value of a Safety and Health Training Matrix

By John Baker, Total Safety Certified Industrial Hygienist

For Industrial Safety and Health Training, Go Total SafetyTraining provides the foundation for protecting the safety and health and improving the well being of workers worldwide. This is recognized by the emphasis placed on training in modern Safety, Health and Environmental management systems standards such as the Occupational Health and Safety Management Systems – Requirements (OHSAS 18001:2007) developed by the British Standards Institution which specifically requires that “(t)he organization shall identify training needs associated with its OH&S risks…”

A training matrix is a planning and communication tool used by safety and health professionals and managers to keep track of an organization’s training needs. It can take many forms as long as it clearly shows what types of training are required for various job positions or specific employees. A manager can then quickly find the required training without sorting through paragraphs of regulations or company policies and procedures. This tool is also useful for scheduling training and allocating resources. A training matrix can also be used for employee evaluation and to support a corrective action plan for an employee or to improve organizational compliance with a governmental regulation or company policy, highlighting the new training that must be done by a specific date.

A training matrix is often designed as an electronic spreadsheet. Rows and columns are created with headers such as job position or employee name, specific training topic, training dates, and other useful information. Typically a training matrix would include a separate column for initial orientation on company safety and health policy and procedures, and for refresher training on these topics, in addition to training required by governmental agencies such as the US Department of Labor, Occupational Safety and Health Administration (OSHA), the US Environmental Protection Agency (EPA) and their state and local counterparts.

For example, typical OSHA training requirements for general industry include: employee emergency and fire prevention plans; hearing and respiratory protection; fire extinguishers, powered industrial trucks; and hazard communication. OSHA standards regarding specific chemicals such as asbestos, benzene, lead and hexavalent chromium have very detailed training requirements.  Of course, there are numerous important safety and health topics such as heat stress, proper lifting and office ergonomics for which OSHA does not have a standard, and these topics should be added to the training matrix as well.

First, fill in the left hand column with the job positions and names of the employees who should be trained. Next, each topic can be used to fill out its own column on the training matrix. The last step is to place an “x” or use a specific color code to indicate which training topics by column need to be scheduled and completed by that employee. For each training topic, one might even split up the column into sub-columns to indicate dates initial and refresher training completed, and pass/fail status.

OSHA has provided an excellent brochure highlighting specific training requirements (as of 1998) on their web-site at http://www.osha.gov/Publications/2254.html.  Of course, the manager should check the current OSHA regulations for updated requirements.

A training matrix, while informative and self-explanatory, should not be used as a substitute for hands-on management. A manager should still meet with employees and explain the requirements and the reason behind them.

For additional information on safety and health training, contact us at 888.44.TOTAL.

Communications Solutions, Fall Protection Service Solutions, Fire Protection Service Solutions, Gas Detection Service Solutions, Industrial Medical Management Services, Industrial Safety Services & Equipment, Respiratory Service Solutions, Safety Equipment for Rent

Total Safety Releases New Edition of Services and Products Catalog

Total Safety releases a new edition of its Services and Products Catalog.Total Safety, the leading global provider of integrated safety solutions and services, announces the release of its new services and products catalog. Current with industry trends, the catalog presents the latest industrial safety services and equipment and keeps customers outfitted with the best the market has to offer.

State-of-the-Art Safety Equipment and Services

Featuring a range of safety equipment — from the tried-and-true to the latest-and-greatest — Total Safety’s catalog is designed to give the reader a glimpse at equipment and services that are geared towards keeping their workers, community and environment safe.

The catalog features eight sections of safety equipment for rent and/or purchase, including:

Respiratory Protection
Gas Detection
Fire Protection
Communications
Fall Protection
Safety
Marine Specialties
Specialty

“Customers can shop a wide range of equipment for rent or purchase and be assured that they are serviced by a company who will stand behind it, ” emphasizes Mark Barker, Total Safety vice president of global sales. “In addition, we offer in-house certified technicians, materials management services and more to support that equipment and keep workers safe.”

Readers will find a section dedicated to Total Safety’s comprehensive services. “We wanted this catalog to not only be a quick highlight of the equipment we offer, but we wanted to showcase what makes us the best in the industry — our people. Our people are trained experts in their field and provide top-notch safety services that keep people and the environment safe globally,” said Charles Ripoll, Total Safety executive vice president of marketing and business development.

Total Safety collaborated with Marion Interactive to manage the new catalog’s concept, development, electronic production and printing. Marion Interactive has been a long term partner of Total Safety, and also designed and manages the Total Safety website. In addition, Marion Interactive developed and programmed the technology for the online catalog. “It takes writers, designers, programmers and a creative design team to build a product like this, and all must work closely with Total Safety sales, procurement, and marketing staff,” said Marion Interactive CEO Aaron Ellisor. “Great communication between client and supplier is key to success.”

Catalogs can be ordered by calling 888-448-6825 or online at totalsafety.com.

Online Catalog

Total Safety is updating the online version of its catalog to give clients easier access to the rental or purchase of safety equipment.

Industrial Safety Services & Equipment

Total Safety Wins ‘Best in Category’ by Houston Business Roundtable

Total Safety Wins Best in Category from Houston Business RountableMay 23, 2012 – Total Safety, a leading global safety services company, was honored by the Houston Business Roundtable as the “Best in Category” safety award from a field that included 134 companies across the award categories. The Houston Business Roundtable, whose membership consists primarily of refining, chemical and energy companies, held their 25th Annual Safety Awards banquet on Friday, May 18th, to present Safety Excellence awards to contractors. Total Safety won the honor in the “Technical Support – Large” category and was nominated by several customers.

“We are proud of the collective effort of the teams that have been recognized for their demonstrated expertise, dedication, and quality, and we are grateful for the support of our customers. This award is reflective of Total Safety’s goal to be the best in the business and make every day a safe and productive one. We believe that taking care of our people and our customers’ team members is truly a noble endeavor,” said David Fanta, Total Safety’s Chief Executive Officer.

Dave Myslenski, Vice President of Operations, noted, “We take the safety of our people and our customers very seriously – it’s our focused mission. To be recognized by the Houston Business Roundtable and our customers is a testament to the safety values at the core of Total Safety.”

The Houston Business Roundtable award comes on the heels of Total Safety earning 16 national and regional safety awards in 2011.

About Total Safety
Total Safety, a Warburg Pincus portfolio company based in Houston, Texas, is the world’s premier outsourced provider of integrated safety and compliance solutions and the products necessary to support them. As the global safety solutions leader, Total Safety provides services and products to support: onsite safety, turnaround safety, gas detection, respiratory protection, rescue, safety training, fire protection, safety compliance and inspection, industrial hygiene, onsite emergency medical treatment/paramedics, communications systems, engineered systems design, and materials management. It operates from more than 134 locations in 18 countries to ensure the safe Wellbeing of Workers Worldwide (W3).

For additional information and inquiries, contact:
Stenning Schueppert
Vice President – Strategy, Marketing & Corporate Development, Total Safety
713-353-7182

Environment Health and Safety (EHS) Services, Gas Detection Service Solutions, Industrial Hygiene, Turnaround Support Service Solutions

Industrial Hygiene Elements of a Successful Turnaround

By John Baker, Total Safety Industrial Hygienist

Previously, Total Safety has emphasized the importance of including the need for IH resources during the planning of the turnaround to ensure that the exposure of employees (and possibly contractors) to airborne chemicals, silica, asbestos, noise, heat, radiation and other health hazards is monitored and controlled.

Pre-planning is essential for a successful turnaround because the specialized equipment and materials needed to test or detect certain materials and physical hazards may not be available on a moment’s notice.  This is especially true for a chemical plant turnaround that may require testing for aldehydes, amines, cyanides or other chemicals not typically tested for in refinery turnarounds. Filter or sorbent media that are pre-treated with specific reagents are necessary to monitor for aldehydes, ketones  and amines. Pesticide manufacturing plants typically require specialized testing and lab procedures to properly measure the materials of interest. Some materials, such as certain isocyanates, require the samples to be refrigerated and analyzed in the laboratory as soon as possible for accurate results. Polynuclear aromatic hydrocarbon air samples should be wrapped in foil and shipped refrigerated by overnight delivery to prevent degradation by sunlight and elevated temperatures. Testing for hexavalent chromium fumes while welding, cutting or arc gouging on stainless steel or high temperature alloys requires different filters and lab testing than for welding fumes on common steel. Chemicals that have high ionization energies, such as methanol or sulfur dioxide, may not be detected by a typical hand held or area photoionization detector, so a modified or different type of instrument would need to be used in that case.

Another point to be clarified well before the turnaround begins is the scope of work regarding confined space entry permits and hot work permits. Just because an IH technician is walking through a unit on the way to an assignment does not mean that he or she is under contract or allowed to “sniff” a space and “sign off” on a confined space or hot work permit. Generally, a supervisory employee of the owner or operator of the refinery or chemical plant is the person with the knowledge of the process and the equipment, and therefore, the associated hazards, who should be responsible for the final sign off on such permits. If this is not clarified at the planning stage, it could cause undue delays and confusion during the turnaround itself. The ventilation of confined spaces is another aspect of turnarounds that benefits from detailed prior planning. The location of the intake of the air supply must be in a clean, uncontaminated area, and the exhaust should likewise be directed away from workers, trailers or areas used for plant traffic. Be careful where “vac” trucks are discharging their exhaust as well.

Thought should also be given to which pre-turnaround activities need as much or more IH scrutiny than the maintenance, repair or replacement work itself. Some of the greatest potential for exposure occurs while units are being brought down and drained and purged. The potential for oxygen deficient atmospheres when nitrogen purging, or reactions of residues when using high temperature steam, should be considered and appropriate monitoring and PPE provided.

Thinking ahead and communicating in detail with the turnaround’s project engineering team about what, when, who and how of each work task will ensure that the IH resources committed to the turnaround are available when and where they are needed.

For additional information about pre-planning for your turnaround, contact us at 888.44.TOTAL.

Uncategorized

Houston-Area Webb-Murray Offices Relocate to One Central Office

Webb-Murray, a Total Safety company, is now at a new location. Our new facility will house our locations formerly in La Porte, Pasadena, Clear Lake and Baytown, Texas.

New Address:
4210 Malone Drive
Pasadena, TX 77507
Business: 281.291.4800
Fax: 281.218.4990

Webb-Murray provides the necessary services to ensure reliable operation at the lowest total cost throughout the life cycle of your fire protection system. Look to Webb-Murray for complete project engineering and design, procurement and supply, installation, commissioning and FAT testing, training, inspections, repairs and modifications, and technical support.

As always, look to our experts at Webb-Murray for exceptional service, proven techniques and certified expertise that meet your needs.

Environment Health and Safety (EHS) Services, Industrial Hygiene, Respiratory Service Solutions

Handling Petroleum Coke in a Safe and Healthful Manner

By John Baker, Total Safety Certified Industrial Hygienist

For Environmental Health and Safety Services, Go Total SafetyPetroleum coking is an environmentally responsible recycling process used in some oil refineries to make the most use of hydrocarbon residuals that otherwise would go to waste. As safety and health professionals, we are sure to control the high temperature and pressure used in the coke domes to “bake” the volatiles out of the coke and the drill and high pressure water sprays used to cut the coke out of the coke domes.  However, critical safety and health hazards are present in the material handling processes used to move petroleum coke to storage and ultimately, to the customer. Enclosed conveyors are often used to move the coke into a storage building and then onto docks for loading onto barges, ships or to land based transportation loading facilities. The rollers moving the conveyor belt, the motors powering the rollers, vibrating screens and the limited space for personnel movement and access within the conveyor structure all present potential physical and electrical hazards which must be addressed in the Job Safety Analysis for production and maintenance tasks. Personnel must perform constant maintenance of the conveyors, often spending a considerable portion of a work shift crawling under conveyors to vacuum or sweep and shovel spillage. Even if the vacuum system is in top condition, the awkward space constraints of the conveyor gallery present ergonomic challenges that must be reviewed on a case-by-case basis.

A potentially catastrophic hazard which must be controlled in coke handling operations is the possibility of a combustible dust explosion or deflagration. Petroleum coke is readily able to form dust clouds of finely divided, combustible material. OSHA’s National Emphasis Program for Combustible Dust (CPL-03-00-008) emphasizes the need for administrative and engineering controls including immediate housekeeping, prevention of ignition sources, ventilation with spark detection and explosion/deflagration suppression systems, explosion venting and other  pressure relief devices, when a combustible dust layer exceeds 1/32 of an inch (about the thickness of a typical paper clip) on more than 5% of the floor area of a facility or any given room.

Total Safety studied the dust exposure potential of a petroleum coke handling operation at a large refinery that shipped its coke on ocean going vessels. Particle size analysis of the bulk coke product indicated that throughout the material handling process, more than 65% was smaller than the 40 mesh or 425 micrometer size that OSHA, NFPA and other authorities use as a first step in assessing the potential to form a combustible dust cloud. The bulk coke had less than 5 percent in the “respirable” particle size range of 4 micrometers; however the dust which wafted off the bulk material at transfer points as measured by an optical particle counter indicated that the majority of the airborne dust was in the “respirable” range. Personal samples of airborne dust were collected on filters connected to air sampling pumps worn by each worker. The filter cassettes were wrapped in aluminum foil before sampling and kept refrigerated afterward to prevent degradation of the collected chemicals. The collected dust was weighed and then chemically analyzed for “coal tar pitch volatiles (CTPV).”  Two of the samples exceeded 0.2 milligrams of CTPV per cubic meter of air and were further analyzed for specific compounds within the “polyaromatic hydrocarbon (PAH)” chemical category. Neither sample showed any detectable amounts of PAH compounds.  NIOSH approved half mask respirators with P100 filters provided adequate protection if properly worn according to manufacturer’s recommendations.

In summary, petroleum coke is an economically important recycled material which can be managed in a safe and healthful manner when the associated hazards are anticipated, recognized, evaluated and controlled in a systematic program.

For additional information regarding the health and safety of your workplace, call us at 888.44.TOTAL.

Environment Health and Safety (EHS) Services, Industrial Safety Service Centers, Respiratory Service Solutions

Total Safety Leads Hydrogen Sulfide Safety Discussion with China’s Sinopec Group

Total Safety recently hosted executives from Sinopec Group, one of the largest Chinese state-owned petroleum and petrochemical enterprise group, at its La Porte, Texas, facility to lead a discussion on hydrogen sulfide (H2S) safety.Total Safety recently hosted executives from Sinopec Group, one of the largest Chinese state-owned petroleum and petrochemical enterprise group, at its La Porte, Texas, facility to lead a discussion on hydrogen sulfide (H2S) safety. The meeting was part of an initiative of the Houston Mayor’s Office of International Trade & Development.

Sinopec executives were visiting Houston to meet with upstream energy leaders and, as part of that trip, requested to meet with a health, safety and environmental (HSE) services company with expertise in (i) risk identification, risk assessment and risk control, (ii) emergency preplanning and contingency planning, and (iii) the development of gas fields with high hydrogen sulfide content.

“With our worldwide capabilities and expertise concerning hydrogen sulfide (H2S), Total Safety welcomed the opportunity to share our experience and expertise around risk identification, assessment and control,” said Jude Taylor, regional general manager for Total Safety. “The safety of workers worldwide is paramount and the discussion focused on how to build on its efforts of continued improvement in this area of operations.”

During the facility tour, Sinopec executives witnessed first-hand Total Safety’s safety culture and how it educates its customers on the importance of safety in the workplace. They also learned about Total Safety and its entire suite of industrial safety services and equipment.