The CARBON DIOXIDE SAFETY Program - PowerPoint Presentation

The CARBON DIOXIDE SAFETY Program has been published by the RFA to help facilities understand CO2 health effects and control CO2 exposuresFree download at: www.ethanolrfa.org Purpose

The RFA’s CO2 Safety Program:Provides an overview of the chemical and physical properties of carbon dioxide, Explains where CO2 comes from and how it is produced in the ethanol industry;

The RFA’s CO2 Safety Program:(cont.)Discusses the many uses of CO2; Presents accidents that have resulted from CO2 overexposures; Reviews the U.S. established worker exposure limits;

The RFA’s CO2 Safety Program: (cont.)Covers the health and physical hazards associated with carbon dioxide in all its forms,Gives detailed procedures and methods for eliminating these exposures – or at least controlling them to an acceptable degree;

The RFA’s CO2 Safety Program: (cont.)Gives specific safety awareness information, andExplains in detail safe handling procedures and specific methods for hazard minimization

The RFA’s CO2 Safety Program: (cont.)This Carbon Dioxide Safety Program also has 4 training programs Training modules are independent of each other and can be given in any order

Module 3: Developing a Site CO2 Management Program Renewable Fuel Association

Developing a Carbon Dioxide Management Program Best Practices for Recognizing, Preventing and Controlling Unsafe Levels of Carbon Dioxide

Steps in the Process:Recognize Where Carbon Dioxide Can Accumulate – Especially during Different Processes, Seasons and Weather Conditions Develop a Carbon Dioxide Facility Review ProcessEvaluate Areas and Conditions of Special Concern

Steps in the Process: (cont.)Evaluate and Upgrade Confined Space Entry Procedures Take a Fresh Look at Standard Operating Procedures and JHA’s (Job Hazard Analyses)Provide Education, Information and Resources

Steps in the Process: (cont.)Process Controls Materials of ConstructionWarning SignsPersonal Protective Equipment Working with or around Gaseous CO2 at or above 15 psia (30 psig)Working with or around Liquid or Solid CO2

Recognize Where Carbon Dioxide Can Accumulate – Especially During Different Processes, Seasons and Weather Conditions, andProtect Workers

Ground floor locations and other low-lying areas, including those outdoors and around the water treatment containment areas (including anaerobic and aerobic tanks),  Identify Where CO2 Can Accumulate

In grain receiving areas due to new crop respiration and limited ventilation, including under the corn receiving tunnels, Where CO2 Can Accumulate (cont.)

inside the buildings that house the fermentation tanks, the fermentation tanks themselves, Where CO2 Can Accumulate (cont.)

yeast propagation, grain receiving and unloading areas, hoppers, slurry/mash “steep” tanks, and drains that collect liquid materials and pump it out  Where CO2 Can Accumulate (cont.)

Areas where carbon dioxide is collected and discharged, especially the carbon dioxide scrubber, and baghouse,  Where CO2 Can Accumulate (cont.)

Locations with restricted or limited ventilation whatever the elevation, especially those areas where people need to go only rarely , and Where CO2 Can Accumulate (cont.)

Confined areas and confined spaces, including diked areas around any kind of tank.  Where CO2 Can Accumulate (cont.)

Pressure relief devices (PDR’s), or pressure release valves (PRV’s) often allow CO2 to be vented directly out of process vessels. The CO2 released is one of the significant sources of fugitive CO2 emissions within any production facility. Where CO2 Can Accumulate (cont.)

PRD’s/PRV’s can sometimes stick open or be open for other reasons, then the surrounding areas can accumulate Immediately Dangerous to Life and Health (IDLH) CO2 concentrations in a short amount of time. Where CO2 Can Accumulate (cont.)

Carefully consider the dispersion of CO2 from all PRD’s/PRV’s sources.Where CO2 Can Accumulate (cont.)

Off-gassing from fermenters can cause localized areas of high CO2 concentrations that can be unsuspected. Opening manways and venting PRD’s/PRV’s can result in transient but catastrophically high CO2 levels. Where CO2 Can Accumulate (cont.)

Evaluate the facility for situations where transient exposures could occur, including low-lying areas and during sub-freezing weather. Pay special attention to low wind situations which can cause accumulation of CO2 in outside areas from CO2 stacks.Where CO2 Can Accumulate (cont.)

Develop a Carbon Dioxide Facility Review ProcessConduct comprehensive walk-through surveys of the entire facility looking for areas where carbon dioxide can collect.

Include areas of: limited air exchange; low-lying areas; places where stover, organic waste, and wastewater are stored and can collect; and process areas known to have elevated CO2 levelsDevelop a CO2 Facility Review Process (cont.)

Conduct these plant surveys with a hand-held CO2 monitor. Develop a CO2 Facility Review Process (cont.)

Be sure to survey on a day when the air is still (very little wind, less than 5mph, in order to detect pockets where CO2 can collect. Wind plays a critical part in dissipating CO2Develop a CO2 Facility Review Process (cont.)

Include all areas of the manufacturing site, not just areas known to have carbon dioxide present, such as fermentation areas. Develop a CO 2 Facility Review Process (cont.)

Be sure to survey the facility under both normal and abnormal process conditions to establish normal vs. abnormal CO2 levels.Develop a CO2 Facility Review Process (cont.)

Conduct multiple surveys throughout the year, and repeat walk-throughs during various weather conditions in order to understand any effects that changes in ambient temperatures may have on CO2 levels. Develop a CO 2 Facility Review Process (cont.)

Areas and Conditions of Special Concern Do not allow CO 2 PRD’s/PRV’s to discharge into work areas, especially indoors.

If possible, install or relocate the exhaust stack of the CO2 scrubber at well above the highest structure, and prior to its installation, consider how CO2 disperses from that area. Special Concerns (cont.)

Install piping, plumbing connections, and vents that contain CO2 above grade and in very well-ventilated areas. * Consider plumbing these vents and connections directly into the carbon dioxide scrubber or collection system . Special Concerns (cont.)

Remember, although carbon dioxide is heavier than air, warm or heated CO2 rises and floats away. It can then travel to remote locations as it cools, collecting in unsuspected areas. Special Concerns (cont.)

Carbon dioxide does not necessarily disperse or readily mix with the surrounding air. Prevailing weather conditions or inside air conditions determine the rate of dispersion. Special Concerns (cont.)

CO2 dispersion will depend upon wind direction and speed, air temperature, and even humidity.(high humidity air is much heavier than dry air, limiting mixing.) Special Concerns (cont.)

Implementing the Best Exposure Control MethodsUsing Engineering, Monitors, Work Procedures, Training, Warning Signs, and PPE to Keep Employee Exposures Low

The OSHA Hierarchy of Controls Engineering controlsAdministrative controlsPersonal Protective EquipmentCost is not allowed to be a factor

Identify carbon dioxide monitoring equipment that complements your plant site’s safety program. A wide variety of CO2 monitors are available today at reasonable costEngineering Controls

Consider setting up remote sensors with automatically activated forced draft ventilation and alarms to reduce collection points to a minimum and to warn workers. Could also be tied in to the control roomEngineering Controls (cont.)

Engineering and Process Controls For low-pressure CO2 systems (up to 400 psig):Use schedule 80 threaded pipe with forged steel fittings rated at 2,000 psi (13,790 kPa), OR Seamless schedule 40 steel pipe with welded joints is recommended; ORStainless steel, copper, or brass pipe and stainless steel or copper tubing.

Engineering and Process Controls (cont.)Use acid-resistant materials: certain stainless steels, Hastelloy metals, or Monel metal For use in systems handling CO2 in aqueous solutions

Institute a documented routine inspection and testing program for all equipmentEngineering and Process Controls (cont.)

Evaluate the venting locations of all PRD’s/PRV’s, exhaust piping, and other sources of high CO2 gas. If possible, re-engineer these and vent emission sources outside and high (if permitting allows). Engineering and Process Controls (cont.)

Initiate a routine procedure for reviewing new equipment installations, as well as proposed equipment process and systems modifications I ncluding any time a piece of equipment is changed or added. System and Process Change Reviews

Administrative Controls

Train employees about these exposures areas, the monitoring alarms where elevated levels of CO2 could occur, and precautions to take in these areas of elevated CO2.Require workers wear personal CO2 monitors in those areasAdministrative Controls

Administrative Controls (cont.) Evaluate and upgrade confined space entry procedures Review SOP’s and JHA’s (JSA’s)Provide additional education, information and resources, and Post warning signs

Confined Space Entry: the #1 cause of multiple fatalities in the workplace Evaluate and Upgrade Confined Space Entry Procedures

Facts from the 10-year study of Nitrogen done for the National Chemical Safety & Hazard Investigation Board that apply to CO2 as well:Confined Space Entry (cont.)

In 80% of confined space fatalities, that exact confined space had been entered before without any problems by the same person who died. Confined Space Entry (cont.)

Of fatal confined space accidents, only 7% had signs on them indicating that they were confined spaces. Confined Space Entry (cont.)

In 40% of fatal atmosphere accidents, the hazard was not present at the time of initial entry. Confined Space Entry (cont.)

89% of confined space fatalities were jobs authorized by supervisorsConfined Space Entry (cont.)

35% of the fatalities were the supervisorsConfined Space Entry (cont.)

In this industry, carbon dioxide accumulation is the biggest atmospheric hazard, especially in confined spaces. Protect workers and train them on its hazards.Confined Space Entry (cont.)

If confined spaces are to entered, include carbon dioxide as one of the measured gases on the multi-gas monitors Confined Space Entry (cont.)

Evaluate and Upgrade Confined Space Entry Procedures AnnuallyConfined Space Entry (cont.)

Remember: OSHA minimum compliance mandates annual refresher training for all confined space entry workers in addition to the annual audits and necessary updates to your programConfined Space Entry (cont.)

All contractors working on your site that are working in confined spaces or in support of confined space entry operations, must comply with the federal Construction confined space entry rules as well.Confined Space Entry (cont.)

Take a fresh look at Standard Operating Procedures (SOP’s) and Job Hazard Analyses (JHA’s)/Job Safety Analyses (JSA’s)SOP’s and JHA’s (JSA’s)

Include risks of unsafe levels of carbon dioxide as possible hazards in SOP’s and JHA/JSA proceduresSOP’s and JHA’s (JSA’s) (cont.)

Evaluate standard operating procedures that allow employees to be routinely exposed to carbon dioxide and design new ways to eliminate or at least reduce these exposures. SOP’s and JHA’s (JSA’s) (cont.)

Resist complacency in workers and supervisors that push against change. Just because it has never happened, doesn’t mean it can’t!SOP’s and JHA’s (JSA’s) (cont.)

Resist being proud of what has already been done and be open to additional suggestions for ways to improve protections.SOP’s and JHA’s (JSA’s) (cont.)

Rethink jobs and job tasks that are hazardous but “have always been done that way.”SOP’s and JHA’s (JSA’s) (cont.)

For example, consider the worker who has to open the top hatch (manway) to pour yeast into a propagator. He/she can be exposed to high levels of CO2 whenever doing this job. SOP’s and JHA’s (JSA’s) (cont.)

Consider installing an eductor system to eliminate this injury risk and exposure. Also consider that this worker risks other injuries carrying the heavy containers of yeast up many flights of stairs.SOP’s and JHA’s (JSA’s) (cont.)

When evaluating job tasks and plant areas for ventilation, design ventilation systems to exhaust from the lowest level and allow make-up air to enter at a higher point.SOP’s and JHA’s (JSA’s) (cont.)

When evaluating job tasks and plant areas for ventilation, install local exhaust ventilation where the levels may exceed 2,500 ppm. Levels below this must be maintained to ensure normal cognitive (thinking) skills.SOP’s and JHA’s (JSA’s) (cont.)

Establish a procedure, with equipment, to ensure continuous voice, visual or signal monitoring whenever workers are in areas where the possibility, however remote, of CO2 collecting can occur.SOP’s and JHA’s (JSA’s) (cont.)

Identify work areas and job tasks that may not be routine, that could present great exposures to CO2, or that present a higher risk of hazard exposures to workers.SOP’s and JHA’s (JSA’s) (cont.)

Cover personal protective equipment (PPE) in these safety reviews and training.SOP’s and JHA’s (JSA’s) (cont.)

Provide Additional Education, Information and Resources

Conduct mandatory, comprehensive, and specific training on CO2 safe handling and hazard minimization for all plant employees.Education, Information & Resources

Include carbon dioxide in the Chemical Hazard Communication Program. Education, Information & Resources (cont.)

Educate employees on all aspects of the carbon dioxide detection systems and monitoring equipment. Ensure that they know where personal monitors must be worn, (if not mandatory in all operating areas).Education, Information & Resources (cont.)

List and discuss areas where wearing CO2 electronic monitors should be mandatoryEducation, Information & Resources (cont.)

Train employees on the warning signs postedEducation, Information & Resources (cont.)

WARNING! CARBON DIOXIDE GAS!Ventilate the Area A High CO 2 Gas Concentration May Occur in This Area and May Be Hazardous or Even Cause Death !

Protect, warn and train outside contractors, vendors, and visitors regarding the hazards of possible CO2 exposure and necessary precautionary measures. Education, Information & Resources (cont.)

Personal protective equipment, or PPE, is considered the last line of defense to protect the health and safety of workers. Personal Protective Equipment

When required, make sure it is readily accessible to workers who need it, train them on proper use and limitations, make sure it can be stored safely.Personal Protective Equipment (cont.)

Training on the proper use and limitations of all appropriate employee personal protective equipment, must be done before the initial use. Personal Protective Equipment (cont.)

For specific information on the safety aspects of bulk liquefied CO2, see Chapter 8. Physical Hazards and Including Bulk Shipment of Liquefied Carbon Dioxide. Personal Protective Equipment (cont.)

To minimally comply with the law, the OSHA safety and health standards must be followed to prevent worker injuries, illnesses, and fatalities. It is the employer’s responsibility to know the relevant standards, then abide by them.

5,000 ppm (0.5%) is the legal workplace 8-hour exposure limit for CO2.However, at this concentration, the very healthy and physically fit International Space Station crew experienced headaches, lethargy, mental slowness, emotional irritation, and sleep disruption, even though oxygen concentrations were maintained at 20.9%. CO2 Inhalation Limits

REMEMBER: The legal exposure limit of 5000 ppm was established nearly 50 years ago and does not protect worker safety and health, especially cognitive and other functions.It is the responsibility of your facility to take this information and use it to protect your work force.

CO2 is a toxic gas, can cause serious and permanent medical conditions, and can cause death within minutesEven 1000 ppm can impair cognitive functionKeep plant levels as low as possible where people are working and use ventilation to do this; even if the weather may make this uncomfortable at timesClosing Summary

Closing Summary (cont.)The best way to do this is to systematically conduct CO2 level evaluations in the facilityDevelop and implement specific, on-going methods and programs to keep CO2 levels controlled to as low as possibleDo this through a written Site CO2 Management Program

QUESTIONS?