S U P P LI E R C H E M I CAL

MANAG E M E NT BO O K
QUAL ALL WR K043 CH EM IC AL MANAGEM ENT BOOK VA

I NTRODUCTION

QUAL ALL WR K043 CH EM I C A L M A N AG E M E N T B O O K VA

part

INTRODUCTION
This booklet has been given to you by a company from the OXYLANE.
It is a confidential document, and remains the exclusive property of the OXYLANE.
It may not be forwarded or used by third parties without prior agreement from us.
This booklet is not a contractual document, but a collection of information about
the chemical risk management in a production site.
These requirements are general, independent of any specific industrial or
economic sector.
They can be used as a reference base to help you assess where improvements or
corrective action is required.

00

created by Qualit y D i r e c t i o n - I n d u s t r i a l D i v i s i o n o f O x y l a n e - C o n f i d e n t i a l - M a r c h 2010

Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

SUMMARY
P05 - Part 01 : Identification

P06 - What is a chemical ?

P07 - How to identify it ?

P09 - Part 02 : Hazards

P10 - Ways of exposure

P11 - Corrosive material

P13 - Toxic & Noxious material
P16 - Fire / Explosion

P19 - Part 03 : Emergency : Procedures & Equipment

P20 - First Aid
P21 - Spillage
P21 - Fire

P23 - Part 04 : Storage & Transportation

P24 - Risk


P24 - Safe Transportation

P25 - Storage Guidelines

P28 - Hazardous Waste
P31 - Part 05 : Chemical Risk Analysis
P32 - Responsibility


P32 - Inventory

P32 - Risk Analysis

P36 - Action Plan
P37 - Part 06 : Prevention

P38 - Prevention Plan

P38 - Elimination & Substitution

P39 - Collective Protection

P43 - Individual Protection
P47 - Part 07 : Auditing

P48 - Exposure Follow-up

P49 - Audit Grid - Examples

P51 - Tools

SU M MARY

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P53 - Part 08 : Appendix

P54 - Sources

P54 - International Guidelines

P55 - Training Material

P55 - Information on Chemicals

c r e a t e d b y Q u a l i t y D i r e c t i o n - I n d u s t r i a l D i v i s i o n o f O x y l a n e - C o n f i d e n t i a l - M a r c h 2010

I N TRODUCTION

QUAL ALL WR K043 CH EM I C A L M A N AG E M E N T B O O K VA

part

00

INTRODUCTION
OBJECTIVE ?

Know how to evaluate the chemicals

management of a supplier.

WHY ?

To protect the health of the workers

in production and prevent accidents.
WHO ?

PL Tech, Quality Managers, Buyers, Supplier

health & Safety Managers...
Anyone in contact with chemicals.

created by Qualit y D i r e c t i o n - I n d u s t r i a l D i v i s i o n o f O x y l a n e - C o n f i d e n t i a l - M a r c h 2010

 Par t
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01 - I D E NTI F I CATI O N
- HA Z AR DS
- EM ERGENCY
- STOR AGE & TR AN SPORTATION
- CH EM IC AL R I SK ANALYSI S
- P R EVENTION
- AU DITI NG
- AP P EN DIX

part

01

I D E NTI F I CATI O N

What is a chemical ?
How to identify it ?

c r e a t e d b y Q u a l i t y D i r e c t i o n - I n d u s t r i a l D i v i s i o n o f O x y l a n e - C o n f i d e n t i a l - M a r c h 2010

 QUAL ALL WR K043 CH EM I C A L M A N AG E M E N T B O O K VA

I D ENTI F IC ATION

What is a chemical ?

part

01

Every gas, liquid or solid used in the process, exept water and comprened oil.
- A chemical substance can be found pure or in a diluted form or mixed into
a preparation.
Examples :
acids, dyes, solvents, cleaning agents, detergents, adhesives, drying agents, paints,
oils
At home too! In your garage, kitchen, bathroom
- pesticides, bleach, disinfectant, oil, antiscale

DUST

SOLID

GAS

VAPOUR

LIQUID

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Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

How to identify a chemical ?

Products Name

List of healtth
or physical hazards

Storage and handling

precautions

Hazard warning

Label Pictograms Equivalence

European and International Classifications

I D ENTI F IC ATION

1. Product Label

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c r e a t e d b y Q u a l i t y D i r e c t i o n - I n d u s t r i a l D i v i s i o n o f O x y l a n e - C o n f i d e n t i a l - M a r c h 2010

 QUAL ALL WR K043 CH EM I C A L M A N AG E M E N T B O O K VA

2. Material safety data sheet (MSDS)

MSDSs are information sheets on products that :
- Tells what hazardous chemicals are present in the product
- What the hazards of the chemicals are
- How to protect yourself from the hazards
Are provided for free, in the local language, by the chmicals supplier (mandatory)

3. MSDSs Key information

I D ENTI F IC ATION

Latest update should be less than 3 years old

part

01

Product identification :

- Trade name

- Supplier contact
Identification of hazardous components :

- Name

- CAS number : only way to identify precisely the chemical
(1 chemical substance can have different name but only 1 CAS number).
All existing chemicals have a CAS number.
Physical and chemical properties
Exposure limits (limit allowed in the air)
Fire and explosion data :

- Flash point

- Auto-ignition temperature

- Explosive limits

- Fire fighting means and conditions.
Health hazards (including signs and symptoms of overexposures)
Precautions for safe use: handling, storage and disposal
Protective equipment
Emergency and first aid procedures

4. chemical sheet
Give very brief information on products :
- Name
- Hazards
- Protective measures, including PPE
- First aid procedure
- Safe disposal
Based on MSDS
Written by the Safety Manager of the factory.
Easily understandable.
Posted everywhere the chemical is used and stored

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(cf. p 42/56)

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- I DENTI F IC ATION
02 - HAZAR DS
- EM ERGENCY
- STOR AGE & TR AN SPORTATION
- CH EM IC AL R I SK ANALYSI S
- P R EVENTION
- AU DITI NG
- AP P EN DIX

part

02

HAZAR DS
Ways of exposure
Corrosive material
Toxic & Noxious material
Fire / Explosion
c r e a t e d b y Q u a l i t y D i r e c t i o n - I n d u s t r i a l D i v i s i o n o f O x y l a n e - C o n f i d e n t i a l - M a r c h 2010

 QUAL ALL WR K043 CH EM I C A L M A N AG E M E N T B O O K VA

How chemicals enter the body ?

1. Ingestion (Swallowing)
Chemicals on dirty hands can contaminate food, drinks
or tobacco products.

H A Z AR DS

Chemicals in the air can settle on food or drink and be swallowed.

2. Inhalation (Breathing)
Vapor and dust are breathed in through the mouth or nose.

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3. Skin Absorption

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Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

4. Hygiene rules
No food, drink (or food and drink containers) in the workshop.

Wash your hands before eating and drinking.

Wash your hands before and after going to the bathroom.
Do not wear contaminated clothes outside the workplace.

- Change clothes at the end of your shift.

- Do not take them back home

Corrosive
1. Definition
Bases : caustic soda, ammoniac
Acids : hydrofluoric, sulfuric, acetic

- Violent reactions with water

- Can form explosive mixture or release toxic gas in contact
with other chemicals
- Cause severe burns

H A Z AR DS

Keep the workplace clean.

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02

Oxidizing material: bleach, peroxides

- Can form explosive mixture or release toxic gas when in contact

with other chemicals

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H A Z AR DS

2. Effects on human health

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02

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BURNS !

3. Effects on equipement
Corrosion - Perforation - Leakage

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Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

4. Effect on the environment

Toxic & Noxious

1. Definition

TOXIC :
Capable of causing injury or death.
- Chlorinated solvents, Dimethylformamide (DMF), Isophorone

CARCINOGEN/MUTAGEN/ toxic for Reproduction :

Capable of causing cancer, birth defects, affect fertility.
- benzene, n-Hexane, methylene chloride, chlorobenzene, DMF...

THIS CHEMCALS SHOULD BE REPLACED AS SOON AS POSSIBLE IN PRODUCTION

NOXIOUS :
injurious to health.
- Toluene, xylene, cyclohexane, neoprene glue

SENSITILER/IRRITANT :
Capable of causing inflammations, irritations to the skin, eyes and
respiratory system.
- Methyl ethyl ketone (MEK), isopropyl alcohol,
methyl methacrylate (MMA)....

H A Z AR DS

Pollution

- Burns plants and animals

- Irritations for exposed populations

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ACUTE INTOXICATION :
Massive dose, quick clinical signs.
- may cause nausea, headaches, dizziness, breathing difficulties.
Ex: if you stay a few minutes in a room full of paint and not ventilated,
you feel dizzy or your head aches. You feel better when you breath fresh air again.
- may be fatal or cause permanent damage if inhaled or swallowed, or up on
entering the body through skin contact.

LONG TERM INTOXICATION :

Repeated small dose, irreversible diseases.
Symptoms appearance can take a long time.
- may cause permanent damage as a result of repeated exposures over time:
allergies, cancer, birth defects or sterility.
Ex: if you paint without appropriate protection everyday during 10 or 20 years,
you can develop a cancer.
Ex: if you use toxic glue everyday during your pregnancy, you can loose your baby.

A chemical can cause both acute and long term intoxications

H A Z AR DS

2. Effects on human health

part

02
POISONS !

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Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

3. Pregant & nursing women

Chemicals are transferred by a pregnant woman to her baby.

- Potential consequences : Spontaneous abortions, birth defects.

Chemicals are transferred to the baby by the mothers milk.

- Potential consequences: development disorders

Example of chemicals leading to these effects :

- Surface treatment: lead, cadmium, chromium
- Solvents: N-hexane, DMF (Dimethylformamide), glycol ethers (Cellosolve,
ethylene glycol), Tetrachlorethylene

4. Effects on equipement

H A Z AR DS

Pollution - Contamination

part

5. Effect on the environment

Pollution of air, soil, water

02

Toxic for plants and animals :

- Accumulate in the food chain
- Alter reproduction
- Affect biodiversity
Toxic for exposed populations

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Fire & Explosion

1. Physical and chemical hazards

part

02

2. Chemicals that can lead to these effects

Flammable and Combustible Material
May light and cause a fire when exposed to heat, sparks, flames or as a result
of friction.
= FUEL

Ex: acetone, MEK

Oxidizing Material contribute to the combustion of other material.

May react violently or cause an explosion when contacting combustible materials.
= OXIDIZING AGENT

Ex: peroxydes, oxygen

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EXPLOSION

Compressed Gases
Explosive danger (gases under pressure); may cause container to explode if
heated in a fire or subjected to impact forces.

Ex: all gas in containers.
Dangerously Reactive Material
may explode as a result of shock, friction or increase in temperature; may
explode if heated in a closed container.

Ex: ammonium perchlorate, perchloric acid solutions

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FIRE

HA Z AR DS

fire, explosions, heat generation, noxious gas generation, Spitting of harmful substances

Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

3. Fire Triangle

4. Definitions
Ignition source: A device or item that is capable of generating sparks or enough heat to produce combustion. (electric spark, open flame, cigarette, hot surface)
Flash point : lowest temperature at which sufficient vapors form above a liquid to catch fire
when an ignition source is present.
Auto-Ignition point : temperature at which, in the presence of sufficient oxygen, a material
will ignite on its own and burn (spontaneous ignition).

HA Z AR DS

In order to ignite and burn, a fire requires three elements :

- heat, fuel, and an oxidizing agent, usually oxygen.

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5. Possible Ignition Causes

All potential heat source :
- thermal, electric, electrostatic, mechanical, climatic

Ex.: hot surfaces, sparks, flames

HA Z AR DS

6. Effects on equipement

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03

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Contamination by toxic fumes and gas

Destruction

7. Effects on the environment

Air pollution by toxic fumes and gas
Emission of greenhouse gas (global warming)

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- I DENTI F IC ATION
- HA Z AR DS
03 - E M E RG E N CY
- STOR AGE & TR AN SPORTATION
- CH EM IC AL R I SK ANALYSI S
- P R EVENTION
- AU DITI NG
- AP P EN DIX

part

03

E M E RG E N CY

P R O C E D U R ES AN D EQ U I P M E N T
First Aid
Spillage
Fire
c r e a t e d b y Q u a l i t y D i r e c t i o n - I n d u s t r i a l D i v i s i o n o f O x y l a n e - C o n f i d e n t i a l - M a r c h 2010

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FIRST AID
1. First Aid Procedure

EM ERGENCY

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CALL A DOCTOR

Skin /eye contact / burn :

- Wash thoroughly with RUNNING water for 15 minutes.
- Take off the contaminated clothes under the shower.
Inhalation :
- Remove to fresh air.
Ingestion :
- do not drink
- rinse the mouth with water
- do not swallow the water
- do not force to vomit

2. First Aid Equipment

Eye wash station
Safety shower
Clean and well maintained
Sufficient water supply (for 15 minutes)
Cleaning water collected and treated

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Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

SPILLAGE
1.Spillage / Emergency Procedure

2.Spillage / Emergency Equipment

Absorbents :
- granules
- sand
- pillows
- mat

Barriers

FIRE
1. FIRE / Emergency Procedure
Give the alert / sound the alarm:

- Give precise information :

Where is the fire?

What is burning?

What is being done?

EM ERGENCY

Give the alert

Wear protections
Stop the spreading
Confine the area
If the chemical is a solid : avoid dust production during the cleaning

part

03

Check that nobody is in the fire area.

If the fire is still manageable :

- Take the closest appropriate extinguisher (NO WATER!!!)

- Direct stream at the base of the flames
Confine the area: close doors and windows.
Evacuate the building :

- By the nearer emergency exit

- Go to the meeting point

- Wait for direction from the management / firemen.

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2. FIRE / Emergency Equipment

FIRE BLANKETS

EM ERGENCY

EXTINGUISHERS

part

03

Foam

Water

Paper / Wood / carboards / Textile

OK

OK

Flammable liquids chemicals

petrol, solvent, oil, fats, greases...

OK

Extinguishers should be accessible and checked regularly

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Dry
Powder

OK

OK

Flammable gas
propane, butane,natural gas...
Electrical fires involving electrical
equipment

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CO2

OK

OK

OK

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- I DENTI F IC ATION
- HA Z AR DS
- EM ERGENCY
04 - STO R AG E & TR AN S P O RTATI O N
- CH EM IC AL R I SK ANALYSI S
- P R EVENTION
- AU DITI NG
- AP P EN DIX

part

04

STO R AG E

& TR AN S P O RTATI O N
Risk
Safe Transpor tation
Storage Guidelines
Hazardous Waste
c r e a t e d b y Q u a l i t y D i r e c t i o n - I n d u s t r i a l D i v i s i o n o f O x y l a n e - C o n f i d e n t i a l - M a r c h 2010

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STO R AGE & TR AN SPORTATION

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part

STORAGE RISK

SAFE TRANSPORTATION CONTAINERS

Containers must be labeled, closed and in good condition.
Containers materials must be compatible with the content.
Avoid leaks, spillage and mistakes :

- NO GLASS in workshop (unbreakable containers)

- NO METAL for corrosives (acids, bases, oxidizers)

- NO FOOD PACKAGING.
CONTAINERS MOVERS

04
CHAINED CYLINDERS AND DRUMS

+ Written procedures on loading and unloading hazardous material.

+ Inform the transporters on the hazards of the shipped material.

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Cheminal name

Quantity

Hazard

Incompatibility

Reactions

Transprene 113 M

10*50 L

Flammable

Nitric acid

Toxic vapors

...

STORAGE GUIDELINES
1. Storage Guidelines
Chemicals stored by hazards category.
Check MSDS for pH and compatibility :

- Separate acids and bases

- Separate flammables and toxics

- Separate oxidizing materials and flammables

- Separate compressed gases and flammables
List of stored chemicals up-to-date :

- See MSDS for hazards and incompatibilities,

- Mention possible reactions,

- Available in the storage room.
Damaged, out-of-date and unused chemicals should be eliminated ASAP
(see chemical waste).

COMPATIBILITY

STO R AGE & TR AN SPORTATION

Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

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04
NOT OK

OK

under condition

OK

(see msds)

c r e a t e d b y Q u a l i t y D i r e c t i o n - I n d u s t r i a l D i v i s i o n o f O x y l a n e - C o n f i d e n t i a l - M a r c h 2010

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04

Storage room :

- Separated area,

- Locked, access limited to authorized personnel only,

- Electrical installations protected against explosion (no sparks),

- Sheltered (protection against sunlight and rain),

- Well ventilated, appropriate temperature maintained,

- Hazards identified (warning signs clearly visible, chemical sheets available),

- Secondary containment for hazardous liquids,

- Fire extinguishers,

- Water supply within 10s for eye and body cleaning,

- Spill response kit available.
Containers / Big bags :

- Closed,

- Durably and legibly labeled in a language spoken by workers,

- In good condition (no holes or leaks).
Hazardous liquids on retention tanks.
Heavy containers close to the ground.

- Do not pile up containers!

2. Hazardous Liquids Retention

Collection drain or retention rim around chemical storage.
Retention tanks:

- Material compatible with the stored chemicals.

- Volume equivalent to the largest volume either :
Largest volume of the containers stored on tank

OR

volumes

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3. Retention Example

100 + 20 + 5
= 62,5L
2
or
VMAX = 100L

100 + 100 + 100

= 150L
2

or

4. Compressed Gas Storage

VMAX = 100L

STO R AGE & TR AN SPORTATION

Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

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04
WARNING
Keep compressed gas away from heat and sun.

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HAZARDOUS WASTE
Hazardous waste includes :

- spent chemicals, pesticides,

- used oils, batteries, electrical equipment,

- contaminated clothes and materials,

- empty chemical containers
To respect the environment and national regulations:

- do not mix hazardous waste with regular waste, even in small quantities.

- do not throw up any chemical in the sink or sewer system.

- eliminate hazardous waste as soon as possible.

Should be collected separately :

- Specific and identified containers in the waste production area:

- Use different containers for hazardous waste.

- Do not mix with regular waste.

- Storage in assigned areas :

- Hazardous waste collected in the workshops should be stored as

hazardous chemicals, in a specific building outside the production building.
Should be handled and stored with the same precautions than hazardous chemicals.

- Proper containers :

- Compatible with their content (no metal for acid or caustic waste to avoid corrosion),

- Closed and in good condition,

- Labeled with hazardous waste, name of the waste, warning signs.


- Stored in assigned areas:

- With secondary containment,

- Sheltered,

- Locked,

- Visible warning signs (WARNING HAZARDOUS WASTE),

- Properly ventilated.

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 Should be disposed of by a qualified contractor to be recycled, treated, incinerated or

buried in a hazardous waste landfill.

UNPROPER STORAGE
NOT OK !

STO R AGE & TR AN SPORTATION

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04

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04

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- I DENTI F IC ATION
- HA Z AR DS
- EM ERGENCY
- STOR AGE & TR AN SPORTATION
05 - C H E M I CAL R I S K ANALYS I S
- P R EVENTION
- AU DITI NG
- AP P EN DIX

part

05

CHEMICAL
RISK ANALYSIS

Responsibility
Inventory
Risk Analysis
Action Plan

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CH EM IC AL R I S K ANALYSI S

CHEMICAL MANAGEMENT RESPONSIBILITY

Appoint a chemical products responsible.

- Either the health & safety manager.

- Or someone with good knowledge on chemicals.
will follow all matters concerning chemicals.
( purchasing, storage, handling, waste management )
The Chemical products responsible must:

- Identify the hazards

- Estimate exposure

- Know the country regulation

- Set the appropriate organization : prevention means and emergency procedures.

1ST step : INVENTORY

Compile in a table all the below information for each chemical used in the factory:
What ?
Where ?
How much ?
Why ?
When ?
How ?
Who ?

- Name, chemical family, aspect, hazard , incompatibilities.

- Storage location, place of use.
- Quantity in store, quantity used per year.
- Use.
- Utilization frequency.
- Handling.
- Users.

2ND step : CHEMICAL RISK ANALYSIS

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05

1. Risk Assesment
For each risk :

HEALTH

FIRE

ENVIRONMENT

For each chemical identified in the inventory:

- rating the quantity used and frequency of use gives the potential exposure.

- After rating the hazards, it is possible to estimate the risk potential.

- This estimation gives the priorities of action.

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Chemicals

TYPE, QUANTITIES (Hazards)

EQUIPEMENTS
OPERATING PROCEDURE
OPERATOR

OPERATING CONDITIONS (Exposure)

RISK
2.Quantity Used

Quantity Class

Q product/ Q total chemicals

<1%

1 to 5%

5 to 12%

12 to 33%

> 33%

3.Utilisation Frequency

Use

Occassional

Periodic

frequent

permanent

Day

< 30 min

30 to 120 min

2 to 6h

> 6h

Week

< 2 hours

2 to 8 h

1 to 3 days

> 3 days

Month

< 1 day

1 to 6 days

6 to 15 days

> 15 days

Year

< 15 days

15 days to 2
months

2 to 5 months

> 5 months

Frenquency
Class

CH EM IC AL R I S K ANALYSI S

Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

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0 if the chemical has not been used in more than a year

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CH EM IC AL R I S K ANALYSI S

4. Potential Exposure
Quantity
Class

Exposure
Class

Frequency
Class

5. Hazard Rating (example)

Hazards
Class

Flash Point
> 100C

FP > 70C

FP > 40c

FP > 20C

FP <20C

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Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

Exposure
5

100

1000

10000

100000

1000000

30

300

3000

30000

300000

10

100

1000

10000

100000

30

300

3000

30000

10

100

1000

10000

7.Categorization

Score by product

Priority of action

> 10000

HIGH

100 to 10000

AVERAGE

< 100

LOW

Hazard

CH EM IC AL R I S K ANALYSI S

6.Risk potential (example)

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CH EM IC AL R I S K ANALYSI S

3rd STEP : ACTION PLAN

1- REDUCE EXPOSURE


(substitute, modify the process and equipment, minimize the

number of person exposed)

2- COLLECTIVE PROTECTIONS

(information, ventilation, )

3- INDIVIDUAL PROTECTIONS

Control measures, from the most effective to the least preferable :

1- Elimination / substitution for a less hazardous or volatile chemical;

2- Collective protection

- isolation

- engineering controls (ventilation, pumps, chemicals delivery)

- administrative controls and work practices (information, training)

3- Personal protective equipment.
All strategies are not always applicable.
more than one type of strategy may be needed for best exposure protection.

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- I DENTI F IC ATION
- HA Z AR DS
- EM ERGENCY
- STOR AGE & TR AN SPORTATION
- CH EM IC AL R I SK ANALYSI S
0 6 - P R EVE NTI O N
- AU DITI NG
- AP P EN DIX

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06

P R EVE NTI O N
Prevention Plan
Elimination & Substitution
Collective Protection
Individual Protection
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PREVENTION PLAN

P R EVENTION

Control measures, from the most effective to the least preferable :

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06

1- Elimination / substitution for a less hazardous or volatile chemical;

2- Collective protection

- isolation;

- engineering controls (ventilation, pumps, chemicals delivery);

- administrative controls and work practices (information, training);

3- Personal protective equipment.
All strategies are not always applicable.
more than one type of strategy may be needed for the best exposure protection.

ELIMINATION & SUBSTITUTION

Whenever possible, avoid using chemicals :

- Ex. : Cleaning with water and soap instead of solvents.
Replace all toxic and CMR chemicals
(Carcinogen, Mutagen or toxic for Reproduction) by less hazardous chemicals.

- Eliminate benzene, chlorinated solvents, DMF.

Whenever possible, replace volatile chemicals by less hazardous and volatile ones.

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Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

COLLECTIVE PROTECTION
Avoid human handling.

- Automated processes.
Limit exposure.

- Limited quantities of chemicals in the workshop,

- Closed containers,

- Ventilation,

- Work practices.

1. Avoid Human Handling

AUTOMATED DISPENSERS

P R EVENTION

Inform on hazards.

- Posting,

- Labels,

- Chemical sheet,

- Training.

part

2. Exposure Limitations
Limited amounts of chemicals in the workshop:

- quantity needed for the day / shift only.

06

Closed containers:

- Avoid formation of dust and vapor.
Effective ventilation:

- Limit the workers exposure to chemicals in the air.
Good work practices

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VENTILATION GUIDELINES :
Principle : exhausting contaminated air away from the work area and replacing it with clean
air. It is one alternative to control employee exposure to air contaminants in the workplace.
The design and troubleshooting of industrial ventilation systems should be handled by a qualified ventilation engineer or firms specializing in this field.

P R EVENTION

Ventilation equipment posted as close as possible from emission point.

- Air flow directed away from the workers.

- Air flow adapted to emissions

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06

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Ventilation system equipped with air filters to remove particles

(mechanical, electrical) and gases and vapors (activated charcoal).
Ventilation system well maintained and cleaned, filter regularly changed.

Contaminated air flow directed away from fresh air supply.

for exhausted fumes not to be drawn back into the building

(heating, air conditioning vent, fans, ).
Where will the gas / fumes / vapors go?
=> Check MSDS to know the Vapor Density.
VD of air is 1 => check if the gas is heavier or lighter than air.
Most solvents are heavier than air ! => choose a lower exhaust

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VENTILATION example

WORK PRACTICES :

- Rules defined and communicated by the safety manager of the factory.

Including but not only :

- Mandatory use of PPE when necessary.

- Restricted access to the chemicals storage room.

- Handling of chemicals authorized for trained personal only.

- No handling of chemicals by pregnant or nursing women.

3. Pregnant & Nursing Women

Chemicals are transferred by a pregnant woman to her baby.

Potential consequences : Spontaneous abortions, birth defects.

Chemicals are transferred to the baby by the mothers milk.

Potential consequences : development disorders

P R EVENTION

NO FANS : Fans spread the emissions in all the workshop and contaminate all
the workers !

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Example of chemicals leading to these effects :

- Surface treatment : lead, cadmium, chromium
- Solvents : N-hexane, DMF (Dimethylformamide), glycol ethers
(Cellosolve, ethylene glycol), Tetrachlorethylene

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4. Hazards Information
Employees have the right to know the properties and potential safety and health hazards
of substances to which they may be exposed.
Information must be readily available.
Chemicals must be easy to identify.
Employees must be trained.

P R EVENTION

POSTINGS

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LABELS
Information duplicated on all the sub-containers :

- Pictograms

- Name of the product

- Handling precautions (except on very small container)

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Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

CHEMICAL SHEET EXAMPLE

MEK
Hazards
Vapors highly flammable.
Irritating by skin or eye contact and by inhalation.
Harmful if swallowed.
Safe Use
Use butyl gloves, use goggles or glasses.
Keep away from heat, sparks and flames.
Work only with fresh air supply.
First Aid
After eye contact: Rinse for 15 minutes with water.
After skin contact: Take of soiled clothes. Wash with soap and water. Rinse
for 15 minutes with water.
Disposal

Written by the Safety Manager, based on MSDS.

Easily understandable.
Posted everywhere the chemical is used and stored.

Hazards Information : TRAINING

Before they start working with chemicals, workers must know and understand :

- How to read the chemical safety information (labels, pictograms, chemical sheets),
- The hazards of the products they work with,
- The safe ways of handling those products for them and others,
- The safe storage rules,
- The PPE they should use,
- The hygiene rules,
- How to dispose of the product,
- The emergency procedures.

work permit (renewable every year) for workers in contact with chemicals.
Written records of the training sessions.

INDIVIDUAL PROTECTION

P R EVENTION

Do not pour into sewage or regular bin.

Collect in labeled container.

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06

1.Personal Protective Equipment (PPE)

Personal protective equipment must only be considered as a hazard control measure after all
administrative controls

(Substitution of the most hazardous chemicals, limitation of the number

of workers exposed to chemicals, )
and practical engineering controls

(ventilation, automated process and dispensers)

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have been used and it still remains a need for additional protection.
- PPE must be supplied to workers who do potentially hazardous work.
- Managers must require that PPE be worn.
- Workers must be trained to use this equipment properly.
- Workers must be informed about the health and safety risks of not wearing the required PPE.
- PPE must be appropriate and tested to make sure it fits the worker.

2.PPE : Individual Protections for Chemicals

P R EVENTION

Do not breath vapors and dust

Avoid any contact with the eyes and the skin

Wear personal protective equipment (PPE)

3.PPE : Face & Eyes Protection

Google, spectacles: protect the eyes against spatters of toxic, noxious and corrosive material.

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06

Face shields: protect the face against spatters of corrosive materials.

- Not efficient against dust or toxic and noxious vapors.

Should be kept clean and changed when contaminated

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4. PPE : Respiratory Protections

Masks: protect the throat and lungs against dust and vapors.

Appropriate filtration chosen by the safety manager :

Solvents and toxic dust and mist: filter mask.

- Filter changed at least once a week.

- Filter hermetically closed when not used.

- Mask stored in a non polluted atmosphere.
Filter Codes : written on the filter.
P = Particulates, e.g. dusts, mists (spray), metal fumes.
A = Organic gases/vapors above 65C.
B = Inorganic gases.
E = Acid gases.
K = Ammonia.
AX = Organic gases/vapors below 65C.
Hg = Mercury.
SL = Solid and Liquid (oil based) particulates.

No Hazardous dust and mist (spray) : Disposable mask.

- Choose masks providing a good face seal

- Change mask at each shift (at least every day).

5. PPE : Hands Protections

No knitted gloves (cotton, polyester, nylon, wool)

- Only plastic or rubber gloves chosen by the safety manager according to the chemicals used.

Disposable gloves = NOT RE USABLE !

Chemicals

Latex

Nitrile Neoprene

Carboxylic acids
(acetic)

PVC

PVA

Aldehydes, Esters
(Ethyl or butyl acetate)
Primary alcohols
(isopropyl alcohol)

Ketones
(Acetone, MEK, cyclohexanone)

Btuyl

Teflon/
Viton

Multilayered

Aliphatic hydrocarbons
(n-hexane, cyclohexane...)

X
X

Chlorinated hydrocarbons

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part

Aromatic hydrocarbons
(toluene, xylene, naphta)

Aqueous solutions
(soda, chlorhydric or sulfuric
acid)

P R EVENTION

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P R EVENTION

- Common chemicals in production

6. PPE : Body & Feet Protection

Workers handling chemical must :

- wear the protective clothes and shoes chosen by the safety manager.

- change at the end of the shift and before meals.

- must not take contaminated clothes and shoes at home

(to protect their home and the health of their family!)

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CHEMICALS ARE DANGEROUS : WEAR PPE !

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- I DENTI F IC ATION
- HA Z AR DS
- EM ERGENCY
- STOR AGE & TR AN SPORTATION
- CH EM IC AL R I SK ANALYSI S
- P R EVENTION
07 - AU D ITI N G
- AP P EN DIX

part

07

AU D ITI N G
Exposure Follow-up
Audit Grid - Exampl es
Tools
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EXPOSURE FOLLOW-UP
1. Limitations
The concentration of chemicals in the air should be kept under
Threshold Limit Value (TLV) or Permissible Exposure Limit (PEL).
= level of exposure of the typical worker without risk of disease or injury.

- can be found on the MSDS.

- must respect the local regulation.

AU I DITI NG

These limits can be expressed in 2 different ways :

- Ceiling values (C) : at no time should this exposure limit be exceeded.

- 8-hour Time Weighted Average (TWA) :

average value of exposure over the course of an 8 hour work shift.

2. Measurement
! Collective protection is always required !
(whatever the chemical concentration in the air)
Then, exposure measurement (8h Time Weighted Average and Ceiling value) should be
performed to check the efficiency of the collective protection.
HOW ?
WHERE ?
WHEN ?

- Gas detector with pump to simulate the breathing.

- At the most exposed post. Captor at breathing level.
- At least once a year.

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3. Medical Follow-Up
For each worker in contact with chemicals:

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- Exposure sheets with : name of the chemical, collective and personal protection,
level, duration and frequency of exposure.
- Annual medical check-up reports.
- Record of accidents, sick leave and occupational disease.

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AUDIT GRID : WHAT TO CHECK ?

3.4 Global risk analysis: (See hazard rating)

- Chemical risk analysis : Available? Complete? Relevant? Update frequency?

- Effectively implemented in the factory?
3.5 At the sickbay, check:

- Availability of MSDS?

- Register for frequency and gravity of :

> accidents due to chemicals (including benign ones),

> professional diseases.

- register of actions taken after accident ?

3.8 Training:

- record of the training sessions?

- workers handling chemicals have been properly trained?
3.9 Are pregnant women :

- handling chemicals?

- exposed to solvents (in the workshop, production lines)?
3.12 Ventilation:

- Are all chemicals storage or handling areas efficiently ventilated ?

- How often is the chemicals concentration in the air controlled ?
3.13 Check cleanliness of chemical storage and workshops:

- are chemical containers clean and closed?

- are machines and equipment contaminated by chemicals?
3.18 Workplace safety:

- are transportation means available and adapted for chemicals?

- Is there any risk of chemical spilling?
3.23 Neither food/drink nor food/drinks containers in workshops or chemical storage
room.

NOT OK !

AU I DITI NG

3.7 Emergency procedures:

- adapted to chemicals : first aid, spillage, fire?

- known and communicated?

- emergency material available ?

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3.28 Workshop ventilation: (See ventilation guidelines)

- do workers handling chemicals work with proper ventilation at their work station?

- is the air flow directed away from the workers?

- is the ventilation system regularly and properly maintained?
3.29 Chemicals storage room: (See storage guidelines)

- is chemical storage separated from the workshop?

- is it sheltered?

- is it locked and accessible to authorized personnel only?
3.30 Chemicals storage ventilation: (See ventilation guidelines)

- is the ventilation exhaust directed away from the workshop and any air intake?

- is the temperature well controlled?
3.31 Incompatible chemicals: (See labels and compatibility table)

- Are all containers properly labeled?

- Are incompatible chemicals properly separated?

- Are liquid chemicals placed on empty and clean retention tanks?

AU I DITI NG

3.32 Chemicals containers: (See labels and containers guidelines)

- Are containers materials adapted (no glass, no food containers)?

- Are containers materials corroded? closed?

- Are containers materials legibly labeled, in the workers language?

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3.33 Workers handling chemicals: (See training and PPE)

- Are they aware of the hazards of the chemicals they use?

- Do they know how to protect themselves and others?

- Are they wearing the adapted PPE?

- Do they know what to do in case of emergency?
3.34 Information on chemicals: (See hazards information)

- Are MSDS available for all chemicals? Complete? Up-to-date?

- Are chemicals safety data sheets clear and up to date?

- Are CSDS available next to the chemicals (workshop and storage)?

- Are CSDS known and understood?
3.35 Emergency means: (See emergency guidelines)

- Are they reachable easily and easy to find?

- Do safety showers and eye wash have water supply for 15 minutes?

- Are the fire fighting means adapted to chemicals (no water)?

- Are spill response kits available?

- Do workers know how to use them?
3.36 Personal protective equipment: (See PPE)

- Are PPE adapted to the chemicals (no dust mask for solvent, no textile gloves)?

- Are PPE regularly cleaned and changed (at every shift for disposable gloves and

masks, filters changed every week on masks)?

- Are PPE available everywhere chemicals are used or stored?
3.37 Workers and PPE: (See PPE)

- Do workers handling chemicals wear the PPE mentioned on MSDS

(protective clothes, protective shoes, goggles, gloves, masks)?

- Are PPE properly and regularly worn by workers?

- If not, check why:

- not available? bad training? wrong size? too heavy?...

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3.38 Posting: (See hazards information)

- Is there a posting on hazards, PPE and emergency procedures?

- Is it clearly visible?

- Is it understood by all workers?
3.55 Fire prevention:

- Are flammable chemicals handled and stored away from any heat source?

- Are flammable chemicals stored away from any oxygen source?

- Are chemical wastes safely and regularly disposed of?

AU I DITI NG

NOT OK !

AUDIT TOOLS

part

Portable smoke generator.

- Air current detection:

- Ventilation systems check

- Smoke detectors check

- Leaks detection

07

Flow meter.

- Air flow measurement

- Ventilation systems check
Test tubes.

- Gas concentration measurements

- Exposure limit check

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1. Audit tools and PPE International Suppliers

DRGER SAFETY
- www.draeger.com
3M
- solutions.3m.com
SPERIAN (ex-BACOU DALLOZ)
- www.sperianprotection.com

AU I DITI NG

MSA
- www.msanet.com

part

2. Use Common Sense !

Every factory is different,
Every process is different.
Each solution should be adapted to the situation.

07

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Par t 01
Par t 02
Par t 03
Par t 04
Par t 05
Par t 06
Par t 07
Par t

- I DENTI F IC ATION
- HA Z AR DS
- EM ERGENCY
- STOR AGE & TR AN SPORTATION
- CH EM IC AL R I SK ANALYSI S
- P R EVENTION
- AU DITI NG
0 8 - AP P E N D IX

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08

AP P E N D IX
Sources
International Guidelin es
Training Material
Information on Chemicals
c r e a t e d b y Q u a l i t y D i r e c t i o n - I n d u s t r i a l D i v i s i o n o f O x y l a n e - C o n f i d e n t i a l - M a r c h 2010

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SOURCES
INRS: French only

- http://www.inrs.fr/

AP P EN DIX

Material and equipments pictures:

- French - http://www.manutan.fr/

- English - http://www.keyonline.co.uk/

part

08

INTERNATIONAL GUIDELINES
International Labour Organisation : English
C170 Chemicals Convention, 1990:

- http://www.ilo.org/ilolex/cgi-lex/convde.pl?C170
Recommendations Chemical safety:

- http://www.ilo.org/public/english/protection/safework/cops/english/download/
e931998.pdf
Organisation Internationale du Travail : French
C170 Convention sur les produits chimiques, 1990 :

- http://www.ilo.org/ilolex/cgi-lex/convdf.pl?C170
Recommandations Scurit chimique :

- http://www.ilo.org/public/english/protection/safework/cops/french/download/
f931998.pdf

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Q UA L A L L W R K 0 4 3 C H E M I C A L M A N AG E M ENT BOOK VA

TRAINING MATERIAL
CIS: International Occupational Safety and health Information Center

- FR: Modules de formation la scurit chimique

http://www.ilo.org/public/french/protection/safework/cis/products/safetytm/toc.htm

- EN: BASICS OF CHEMICAL SAFETY

http://www.ilo.org/public/english/protection/safework/cis/products/safetytm/toc.htm

INFORMATION ON CHEMICALS
International Program on Chemical Safety : INCHEM

- http://www.inchem.org/
Material Safety DataSheets :

- http://www.msds.com/
ESIS : European chemical Substances Information System

- http://ecb.jrc.ec.europa.eu/esis/

AP P EN DIX

European Agency for Safety and Health at Work :

- EN: Dangerous Substances - SME friendly material

http://osha.europa.eu/en/good_practice/topics/dangerous_substances/sme.stm

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