guidelines · 2004. 8. 7. · accumulation of heat, thermally unstable products can generate...

GGUUIIDDEELL IINNEESSfor the safe

f o r m u l a t i o n

and pack ing

o f c r o p

p r o t e c t i o n

p r o d u c t s

CARE•FOR•THEE N V I R O N M E N T

THESE GUIDELINES ARE

INTENDED TO COMPLEMENT THE

REQUIREMENTS OF ANY LOCAL

AND NATIONAL LAWS AND

REGULATIONS, AND ALSO THE FAO

INTERNATIONAL CODE OF

CONDUCT ON THE

DISTRIBUTION AND USE OF CROP

PROTECTION PRODUCTS.

THE INFORMATION CONTAINED

IN THIS BOOKLET IS ACCURATE

TO THE BEST OF THE

KNOWLEDGE OF

CROPLIFE INTERNATIONAL,

BUT NOLIABILITY WHATSOEVER

CAN BE ACCEPTED IN RESPECT OF

THE USE OF THIS INFORMATION

NOR IN RESPECT OF ANY

ADVICE CONTAINED HEREIN.

Guidelinesfor the safe

formulation andpacking of

crop protectionproducts

1

Formulation and packing… 25/10/02 17:36 Page 1

2


PageForeword 2Introduction 41. Hazards 7

2. Organisation and management 19

3. Location and buildings 27

4. Formulation and packing facilities 37

5. Occupational health, hygiene 53

and personal safety,fire/explosion prevention and emergency planning

6. Environmental protection 71

7. Checklist 85

Definition (Glossary) 103

Useful references 105


IntroductionVery few crop protection product active ingredients are capableof being used in the field just as they are. Most have to beformulated - made into usable products - and all need packing forstorage, transportation, sale, and for convenient use. Thedevelopment of high quality formulations and packs, whichneed to meet local standards as well as national andinternational requirements, is an integral part of crop protectionproduct research and development.

Compared with the handling of closed packs during storage andtransport there is a greater risk for workers in formulation andpacking plants who may come directly into contact with thechemicals during normal working operations.

To cope with possible hazards, specific procedures andprecautions must be adopted. In particular, this means that thesiting, the design and maintenance of buildings and equipment,as well as organisation of normal and emergency situations,must be planned and managed with special care.

These guidelines show how this can be achieved in formulationand packing operations. Other related activities (e.g. qualitycontrol, storage) are mentioned, but dealt with in detail in otherCropLife International guidelines.

Whilst the guidelines are intended mainly to assist in identifyingareas for improvement in existing plants, they may also be usedtogether with other CropLife International guidelines to giveguidance on the planning of new plants.

The word must is used to indicate the minimum industrystandard acceptable, and the words should and recommendedindicate proven good practices.

A list of relevant technical terms (Glossary) and some usefulliterature references are given in section 7.

«Crop protection products» is the general name used to cover thegroup of chemical products that includes insecticides, acaricides,molluscicides, rodenticides, nematicides, anthelmintics, plantgrowth regulators, fungicides and herbicides.

4


5

Formulation and packing as well as other related activities of a manufacturingplant for crop protection products

wastetreatment

bulkstorage

storageingredients

formulation

packing

administration

storagefinished goods

storagepackagingmaterials

maintenancequalitycontrol


6


HAZARDS

Health hazards 8

Skin contact 8Inhalation 8Ingestion 9

Fire and explosion hazards 10

Hazards due to combustible dusts 10

Fineness of dust and its concentration 10Oxygen concentration 11Auto-ignition 11Exothermic decomposition 11Hybrid mixtures 12Ignition sources 12

Hazards due to flammable liquids 13

Flashpoint 13Minimum ignition energy 14Over-pressurisation 14

Hazards to the environment 14

Product hazard data, hazard classification 15

7


HazardsIn common with all chemical substances, crop protectionproducts and their ingredients should be considered potentiallydangerous, whilst they are being handled.

Such potential dangers can be controlled when formulation and pa-cking equipment are well designed and maintained, and operatingpractices comply with these CropLife International Guidelines.

These hazards include :

- Health hazards;

- Fire and explosion hazards;

- Hazards to the environment.

In any industrial plants, there are hazards which can lead tophysical injury and these must also be taken into account.

Health hazards

Intoxication can be caused by poisonous, corrosive and irritatingsubstances coming into contact with the skin or when inhaled orswallowed.

Skin contact is the most likely cause of poisoning in a cropprotection product plant. Many crop protection products, ineither liquid or solid form, will pass readily through the skin intothe bloodstream. The eyes and the area around the genitals areparticularly vulnerable.

Inhalation is one of the fastest routes of poisoning. This is becausethe toxic substances from fumes, vapours or dusts can passquickly into the bloodstream via the lungs.

8

Skin is no barrier to cropprotection products

Fumes, vapours and dusts passquickly into the bloodstream via

the lungs


Ingestion is the least common cause of accidental poisoning inmanufacturing areas and is most likely associated with eating,drinking or smoking without first washing the hands.

Fire and explosion hazards

To start a fire or an explosion of flammable materials (gas, liquid,solid), the following three conditions must exist at the same timeand place :

- Combustible material

- Sufficient oxygen (air)

- Effective ignition source.

The three requirements for an explosion

9

Note The purpose of this chapter is to help persons withoutspecialised knowledge assess risk of fire or explosion intheir plants. Sections 4 (commencing page 38) and 5 (page61 onwards) give guidance on prevention and especially onexplosion protection measures. However, in all casesspecialist advice should be sought.

CombustibleMaterial

IgnitionSource

Oxygen(air)

Explosion


Hazards due to combustible dusts

Hazards related to combustible dusts are more complex thanthose of flammable gases and liquids. The following providesbackground to the hazards involved.

For a dust explosion, combustible material must be present inthe form of a dust cloud.

Guaranteed absence of one of the three requirements (dustcloud, air (oxygen), or ignition source) can prevent dustexplosions.

The ignition of a dust layer can lead to a fire. The ignition of adust cloud can lead to an explosion. The latter is normallyassociated with rapid build-up of pressure and sudden heat.Even products which cannot be ignited in normal circumstancescan violently explode when finely dispersed in a dust cloud.

Dust explosions may be classified as «primary» or «secondary».A primary explosion usually occurs within equipment which, ifweak, may rupture as the pressure of the explosion rises inside.The turbulence and pressure pulse can then release dust cloudsinto the air outside the equipment which may ignite to producea secondary explosion.

Secondary explosions in plants, when they occur, may often beattributed to poor housekeeping, whereby accumulations offlammable dusts have been allowed to build up on surfaces ofequipment and building. The disturbance and subsequentignition of these materials by the «primary» explosion can easilyproduce a «secondary» explosion of much greater violence.

Fineness of dust and its concentration (explosion limits) Dust/air mixtures can be ignited within a certain concentrationrange (explosion limits). This concentration range is likely toexist at any time inside equipment used in formulation andpacking, and also on the outside if leaking occurs.

The finer the dust :

- The easier the distribution of dust in a cloud;

- The longer the cloud will exist;

- The greater the violence of the explosion;

10

Hazards


- The lower the minimum ignition energy needed.

Oxygen concentrationThe Limiting Oxygen Concentration (LOC) is the oxygenconcentration in a dust/air mixture, below which an explosionwill not occur. This is dependent on the product and thetemperature. In most cases, no dust ignition is possible below anoxygen concentration of 8% volume by volume.

Auto-ignition Auto-ignition of dust can occur when a dust deposit is subjectedto overheating (e.g. from a hot surface in the presence of air).Auto-ignition itself can be an ignition source for dust explosionand exothermic decomposition, both of which can lead to adangerous pressure build-up from reaction/decompositionproducts.

Exothermic decomposition, deflagration of solid materialsSome chemicals or mixtures of chemicals tend to decompose ifheated and self-generate additional heat as they decompose.

The rate of decomposition and associated generation of heatnormally increases exponentially with temperature, whereasremoval of heat will only increase linearly. This can lead to a run-away decomposition or «thermal explosion» where the heatproduced cannot be removed quickly enough.

Relationship between generation and removal of heat in case of decomposition.Within the red section a «thermal explosion» is possible

11

Temperature

Heat generation

Removal ofheat

Am

ount

of

heat

gen

erat

ed

Explosion


Decomposition can be initiated locally in bulk solid materials(e.g. by a hot bearing during a mixing process, or in the course ofgrinding or drying). If such decomposition is self-propagatingthrough the whole mass of product in the absence of oxygen(unlike normal combustion) it is known as deflagration. Adeflagration cannot be stopped by inert gas blanketing, but onlyby fast and effective cooling by flooding with water.

It is important to note that the larger the mass, the lower thetemperature at which there is risk of run-away reaction withultimate auto-ignition or «thermal explosion».

Hybrid mixtures A dust/air mixture which contains a flammable gas and/or aflammable vapour (e.g. from solvents) is known as a «hybrid»mixture. Such mixtures will ignite more readily and explodewith greater violence than dust/air mixtures. The creation ofhybrid mixtures may be possible during the addition of solids toflammable liquids or the use of flammable solvents duringformulation of solids, such as granules. In addition, hybridmixtures can be expected where, under the conditions ofaccumulation of heat, thermally unstable products can generateflammable decomposition gases.

Ignition sources for dusts The following ignition sources must be considered:

- Hot surfaces - (e.g. heaters, dryers, hot electrical equipment,friction heat);

- Fire, naked flames, glowing or smouldering materials -Special consideration must be given to hazards associatedwith welding and cutting operations, not only because ofnaked flames, but also due to risk of scatter of hot metal andslag particles;

- Mechanically generated sparks - Mechanically generatedsparks may have sufficient energy to ignite dust layers ordust/air mixtures. These can be generated by the striking offalling objects or by frictional means. In the latter case,experience has shown that hazard is eliminated if thevelocity of rubbing or striking parts is less than 1 m/sec;

12

Hazards


- Electrically generated sparks - Sparking electrical equipmentcan be an effective ignition source. All electrical equipmentmust be classified appropriate to the zone of use;

- Electrostatic discharge sparks - Sparks produced byelectrostatic discharges are a common cause of fire andexplosion. Electrostatic charges can accumulate onelectrically insulated materials or objects. Excessiveelectrostatic charges can discharge onto earthed conductivematerial, creating sparks which are powerful enough toignite explosive vapour/air, gas/air, or hybrid mixtures.Experience has shown that the energy of sparks fromelectrostatic discharge may ignite dust/air mixtures having asufficiently low Minimum Ignition Energy (MIE).

Examples of where the build-up of electrostatic charges ispossible are :

- During the pulverising of solids;

- During the spraying or splashing of liquids;

- During the flow of materials (liquids, dusts, etc.,) along walls of equipment or containers (e.g. vessels, pneumaticconveyors, lacquered or coated drums, plastic bags, etc.,).

Hazards due to flammable liquids

The main principles explained in the previous paragraphs inconnection with dusts such as explosion limits, oxygenconcentration, auto-ignition, exothermic decomposition andignition sources can generally be used in a similar way forliquids.

The main differences for liquids are :

Flash point The flash point is the lowest temperature of a liquid at which thevapour above the liquid can be ignited. Beyond this temperaturethe liquid can form explosive vapour/air mixtures. If the flashpoint is not significantly above the temperature of the liquidduring operation there will be risk of fire or explosion due tovapour ignition.

13


Minimum Ignition Energy (MIE) The MIE for vapour/air mixtures is generally much lower thanthat for dust/air mixtures. Therefore, electrostatic discharges aremuch more dangerous and must be avoided (see sectioncommencing page 61).

Over-pressurisationIf liquids in a tightly closed container (e.g. tank, drum, etc.,) areheated from outside (e.g. melting device, fire, solar radiation,etc.,) a rapid build-up of pressure can lead to a rupture. This maybe followed by a fire or explosion.

Hazards to the environment

In order to avoid risk of environmental contamination, attentionmust be paid to the biological activity of crop protectionproducts, and in some cases, to their specific ecotoxicologicalproperties such as toxicity to aquatic life.

Threats to the environment include the uncontrolled oraccidental escape of contaminated air from fume or dustextraction facilities or from inadequate disposal of contaminatedwaste water or waste.

Do not let fire-fighting water escape

14

Hazards


The principal threat is the escape of spilled products and ofcontaminated fire-fighting water. This can heavily pollute thearea outside the plant and adjacent streams, rivers or lakes, andis a particular threat to groundwater sources.

During a fire, noxious fumes will be emitted and all smoke,whatever the material burning, must be treated as hazardous.Firemen engaged in fighting the fire will need the protection ofself-contained breathing apparatus. However, an examination ofrecent incidents of major crop protection product fires hasprovided evidence that people working and living beyond theimmediate site of the fire will not normally require evacuation.This is because the rising hot gases are quickly diffused into theatmosphere. Moreover, air normally is slow to penetrate into«closed» rooms. Thus, such people should be advised to stayindoors, close windows and doors and switch off any ventilationsystems. Unpleasant odours caused by very low quantities ofstrongly smelling substances may be detected, even at greatdistances from the fire, and cause alarm, yet they may beharmless.

Product hazard data, hazard classification

Formulation and packing plants can only be operated safely if allhazards of ingredients and formulated products are well-knownand documented (e.g. in the Safety Data Sheet (SDS) and in theProduct Recipe (see section 2, page 21).

The properties of the formulated product are of specialimportance and cannot always be inferred from the properties ofthe individual ingredients.

In most countries, legislation demands that hazardous productshave to be classified and the packs have to be correctly labelledwhen they are distributed.

For transport purposes, hazard labels following the UnitedNations Recommendations on the transport of dangerous goodsare used world-wide (see CropLife International Guidelines forthe safe transport of crop protection products).

15


For the handling of products during their manufacture, storageand use, many countries classify hazardous products in adifferent way from the transport classification. Unlike thesituation during transportation, this separate classification takesinto account that formulation and packing operations involvethe open handling of products.

Examples of hazard symbols commonly used in the European Union

With respect to the fire and explosion hazards duringformulation and packing, both types of classification can givehelp in identifying hazards, but are not suffficientlycomprehensive in themselves.

Plant managers and operators must always refer to theinformation given in the Safety Data Sheet and on the labels.

16

Highly flammable

Toxic

Harmful

Corrosive

Hazards


The data required depends on the individual situation (e.g. typeof product and ingredients, type of equipment and operationalprocedure), but ideally the following information, which maynot necessarily be included in the SDS, should be available :

- Flash point, vapour-pressure, Lower Explosion Limit (LEL);

- Auto-ignition temperature;

- Combustibility (burning behaviour);

- Thermal stability;

- Dust explosion behaviour [e.g. dust explosion class,Minimum Ignition Energy (MIE)].

17


18


ORGANISATION ANDMANAGEMENT

Responsibilities 20

Selection of the personnel 21

Documentation 21

Quality documentation 21Safety Data Sheets 22

Procedures 22

Training 23

Auditing 23

Security 23

Safety, occupational health, hygiene, 23environmental protection

Quality control 24

External affairs 24

Use of contractors 25

19


Organisation and management

Responsibilities

The plant manager must understand that he is personallyresponsible for each of the following :

- Safety and occupational health of the operational staff;

- Security and safety on the site and the protection of the environment;

- Safe production, packing and dispatch of products of good quality;

- Engineering design and maintenance on the site;

- Training and management of personnel;

- Establishment of emergency procedures;

- Good relationships with external organisations and with the neighbourhood.

Responsibility for separate parts of the operation may bedelegated by the plant manager to qualified subordinates, butresponsibilities and lines of communication must be clearly

The plant manager’s responsibilities

20

Formulation and packing

Quality Control

Engineering DesignMaintenance

Personnel Managementand Training

Safety,OccupationalHealth and

Industrial Hygiene

EnvironmentProtection

Security

EmergencyProcedures

External Relations


defined and each subordinate must understand his ownresponsibilities.

A regularly updated organisation chart should formalise alldelegation and communication lines.

Selection of the personnel The plant manager must have a technical background withadequate qualifications and experience.

His delegates must be technically competent and be well trainedin their discipline.

The selection of personnel as well as its training are keyresponsibilities of the plant manager. Each staff member shouldhave training and experience, appropriate to the jobrequirements.

Documentation

The plant organisation must be supported by regularly updateddocumentation.

Quality documentation The quality of products formulated and packed must be defined,controlled and recorded. For these purposes, basic documentsare required as described in the CropLife InternationalGuidelines for the quality control of crop protection products,and should include :

- Specifications

- Recipes

- Analytical methods

- Recording documents.

21


Safety Data Sheets Since each formulated crop protection product and each of itsingredients have their own specific properties, the supplier mustprovide adequate information and in particular, a Safety DataSheet (SDS) for all hazardous products. An SDS for each productshould be available in the plant and contain the informationshown below.

Procedures

All key activities of the site operations must be organisedthrough written procedures known by all persons who have toimplement them. They should include :

- Fire prevention, protection and control procedures;

- Control procedures for contaminated air, water and waste;

22


SAFETY DATA SHEET

1. Chemical product and company identification

………………………………………………………………………

………………………………………………………………………

2. Composition/information on ingredients

………………………………………………………………………

………………………………………………………………………

3. Hazards identification

………………………………………………………………………

………………………………………………………………………

4. First aid measures

………………………………………………………………………

………………………………………………………………………

5. Fire fighting measures

………………………………………………………………………

………………………………………………………………………

6. Accidental release measures

………………………………………………………………………

………………………………………………………………………

7. Handling and storage

………………………………………………………………………

………………………………………………………………………

8. Exposure controls/personal protection

………………………………………………………………………

………………………………………………………………………

9. Physical and chemical properties

………………………………………………………………………

………………………………………………………………………

10. Stability and reactivity

………………………………………………………………………

………………………………………………………………………

11 Toxicological information

………………………………………………………………………

………………………………………………………………………

12 Ecological information

………………………………………………………………………

………………………………………………………………………

13. Disposal considerations

………………………………………………………………………

………………………………………………………………………

14. Transport information

………………………………………………………………………

………………………………………………………………………

15. Regulatory information

………………………………………………………………………

………………………………………………………………………

16. Other information

………………………………………………………………………

………………………………………………………………………


- Site security and emergency procedures in case of personal accident, fire and environmental accidents;

- Standard operational procedures for formulation andpacking (these procedures must include the safety andquality aspects);

- Quality control procedures including sampling, analyticaland recording procedures;

- Engineering procedures for maintenance and modifications.

Training

All personnel working in a formulation and packing plant mustbe adequately trained. A permanent record of the trainingshould be kept. Training should include :

- Knowledge of the product hazards;

- Safe operating procedures of the processes and equipment;

- Fire and accident prevention;

- Procedures in case of emergencies.

Auditing

The plant manager is responsible for auditing the procedures ona regular basis to ensure they are being followed.

Security

To keep out intruders from the site, it is important to have it wellsecured :

- Access to the site must be via a controlled entry procedure;

- During off-duty hours, outside gates must be locked and thesite checked at frequent intervals. Intruder alarms should beconsidered and also the need to organise fast securitypersonnel response.

Safety, occupational health, hygiene andenviromnental protection

Management must pay attention to these subjects, which aredetailed in sections commencing on pages 54 and 72.

23


Qualified advisors, perhaps including external consultants, mayneed to be nominated to deal with these issues.

Quality control

Quality control is an essential element in the formulation andpacking of crop protection products. The principles and guidelineswhich are described in the CropLife International Guidelines forquality control of crop protection products, must be observed :

- The responsibility for product quality must lie with linemanagement and, finally, with the plant manager;

- Production personnel must be organised and trained toproduce crop protection products of good quality and avoidcross-contamination;

- The objective of a quality control organisation must be torelease products only of good quality.

External affairs

The plant manager should maintain an open relationship withthe local community, officials and local emergency organisations(e.g. fire service, hospital, etc.,).

Effective emergency plans for fire, injury and environmentalmatters must be set up. Periodic emergency response tests anddrills should be organised with the community agenciesconcerned.

Use of contractors

From time to time, it may be necessary to employ contractformulators (e.g. to cope with overflow demand).

A contract operation is when another company is employed todo work whereby the employing company provides technology,know-how or materials.

Examples of such activities include :

- Formulation and/or packing

- Warehousing

24



- Transport

- Waste disposal.

It is important when employing contractors, to engage onlythose who are technically competent and who conduct theiractivities so as to avoid unacceptable and unnecessary risk to :

- Health of any person who may be affected by their operation;

- The environment.

The employing company must be satisfied that the contractorcarries out its activities with regard to relevant laws, standardsand codes of practice; and the safety, health and environmentalstandards referred to in these guidelines.

To enable this, a responsible person should be appointed andheld accountable for the appraisal of potential contractors andfor the satisfactory implementation of the contract.

Appraisals must be carried out to ensure that :

- The contractor has in its possession all the appropriateinformation, and understands the hazards of the operation;

- The contractor has the necessary plant and also managerialand technical competence to carry out the requiredoperation.

A written contract should be established between the employingcompany and the contractor which should cover :

- The operation or job to be carried out;

- The provision of Safety Data Sheets, recipes, specifications by the employing company;

- The liability aspects of the operations.

Once the contractor is approved by the employing company, theliability for the operation is assigned to the contractor.

25


26


LOCATION AND BUILDINGS

Location 28Site selection 28Site access 28

Buildings 29Layout 29Construction requirements 29Water reservoir 30Retention 31Drainage 32General ventilation 32Heating 33Lighting 33Noise prevention 33Emergency exits 33Other accommodation 33

Tank farm for bulk storage 34Location 34Design of tanks 34Tank farm arrangements 35Loading and unloading facilities 35Fire protection 35

27


Location and buildingsLocation

Site selection When choosing a site for a new formulation plant, avoid closeproximity to residential areas, schools, hospitals, shopping areas,food processing or storage premises, fresh water sources andsurface water. Preference should be given to isolated locations orsites devoted to industrial development. Also, avoid areas proneto flooding or areas used for water catchment.

Site acces The site must be accessible for both emergency and deliveryvehicles via permanently maintained roads. Ideally, there shouldbe a distance of at least 10m between individual buildings andbetween buildings and the surrounding property to prevent thespread of fire, to provide clear access to each building and topermit reasonable movement of goods. Access for emergencyvehicles should preferably be from two sides but must be fromone side.

Provide suitable access for fire-fighting

28


Buildings

Layout There is no universally applicable layout for a formulation plant.Each plant will need to be designed individually, but a fewimportant points should be taken into consideration whenplanning or assessing a plant :

- The layout should provide ample space to permit easymovement of goods and workers and allow hygienicworking conditions;

- To avoid cross-contamination, areas for processing ofherbicides and plant growth regulators should be separatedfrom areas in which other crop protection products arehandled;

- Powder processing facilities should be segregated from thosefor liquids, either by constructural means or by distance;

- Storage buildings and bulk storage tanks should be locatedto give easy access to the formulation plant;

- Packing areas should be located adjacent to the respectiveformulation areas, preferably in separate rooms;

- The site must be adequately protected from trespassers,preferably by a surrounding wall or fence.

Construction requirements Avoid as far as possible materials which are combustible andwhich could contribute to the spread of a fire. Reinforced concrete frames are preferable to unprotected steelframes. Load-bearing steel members should be protected fromheat by means of insulation, for example sprayed vermiculitecement. Asbestos must not be used.

Floors must be impervious and should have a smooth but non-slip finish for ease of cleaning. External walls may be clad withsteel or similar sheeting, where these are not intended asprotection against risk from external fire. Internal division walls,designed to act as fire breaks, must provide at least 90 minutesresistance and should extend to a height of 1 metre above theroof or have other means of preventing a fire from spreading.The materials best suited to combine fire resistance with physicalstrength and stability are concrete, solid brick or concrete blocks.

29


Fire break walls should extend beyond the roof

Fire walls should not be breached by electrical cables or otherconduits; where this is unavoidable, measures must be taken toinhibit the spread of fire (e.g. by the use of fire retardant sandcups).

Doors in fire-break walls must be of a fire resistance equivalentto the wall itself. They must close automatically in case of fire(e.g. with a fusible link or magnetic device).

Buildings must be adequately protected against lightening.Additional details relating to construction can be obtained fromthe CropLife International Guidelines for safe warehousing ofpesticides.

Water reservoir In locations without a reliable public water hydrant network, areservoir for fire-fighting water must be provided. The volumeof water required for fighting a fire can be up to several m3 perton of product kept on site, unless special precautions areprovided (sprinklers, foam systems, or automatic alarms whichensure a fast response by the fire brigade). The size of the waterreservoir is dependent on the fire potential presented by theplant.

30

Location and buildings


RetentionThere must be means to retain any spills and all the fire-fightingwater.

Retention within a building can be achieved by providing :

- A reinforced concrete bund wall as part of or within the walls of the building;

- Suitable ramps at all fork lift truck entries with a gradient of not more than 1 in 20;

- Suitable sills at all other entry points.

Additional retention volume can often be provided by bundingthe loading and unloading area and other concreted groundoutside the plant buildings. In such cases, provision must bemade for either pumping away rain water or for closing the siteexit drains in the event of fire.

Retaining the total expected volume of water may require animpervious catchment basin. This can be shared betweenvarious buildings or building sections separated by a fire wall, asit is likely that fires may be contained within the section

Bunded area for the retention of fire-fighting water

31


concerned. The capacity must be sufficient to contain the volumeof fire-fighting water which is to be expected in case of a majorfire, and should be approved by the local fire service.

Drainage The site location should be chosen to minimise the risk ofcontaminated water reaching water courses, ground waterreserves or the public drainage system. It is stronglyrecommended that the storm water drainage system isconstructed in such a way that it can conveniently be blocked.

Ideally, there should be no drains at all inside the formulationand packing areas. If drains are necessary, they should be abovethe ground and must not connect directly with waterways orpublic sewers. Drains should end in an interception pit insidethe bunded area.

General ventilation Good general ventilation of the work area is required to provideacceptable working conditions of temperature and humidity.

General ventilation can often be achieved by having open-sidedbuildings. Otherwise, natural ventilation should be provided byvents located in the upper and lower walls and in the roof. Thelower vent must be above bund level. All vents should bedesigned or protected to keep out birds and vermin.

Roof and wall vents together give good ventilation

32



If natural ventilation is inadequate, a forced ventilation systemmust be provided to ensure an air exchange of 2-5 times perhour.

Heating In cold climates, it may be necessary to provide heating withinthe plant. Heating systems should be based on steam or hotwater and the heat source must be segregated from theformulation and packing area. Heaters or steam pipes must belocated to avoid direct contact with stored goods or personnel.

Portable heating units are considered to be potential ignitionsources and must not be used.

Lighting Lighting levels must be set so as so provide safe workingconditions at the workplace.

Lighting fixtures and switches must comply with electricalzoning as outlined in the section commencing page 61.

Noise preventionSeparate rooms must be provided for equipment which is likelyto generate excessive noise but does not require continuousattendance during operation (e.g. air-compressors, powergenerators, etc.,).

Emergency exits Exits other than the main door must be available for emergencypurposes. There must be at least two exits in every manufacturingroom. These should be positioned so that personnel inside theroom cannot be trapped.Emergency doors from upper storeys should open on to anescape balcony.

Emergency exits must be clearly marked and kept clear ofobstructions. They must be designed to be easily opened fromthe inside at all times. They should preferably be provided witha quick opening device.

Other accommodationIdeally, non-production facilities (e.g. offices, amenities, etc.,),should be accommodated in separate buildings. Where suchfacilities are located within formulation and packing buildings,

33


Keep emergency exits free

they must be segregated from the formulation and packing areasand the construction should be designed to provide at least onehour of fire resistance. A means of exit other than via the plantmust be provided.

Tank farm for bulk storage

Location Tank farms must be considered separately from a safety point ofview. Installations should be set apart from other formulationplant and buildings. It may also be necessary to segregate thetank farms internally by means of walls or barriers.

Design of tanksConstruction material for storage tanks is dependent on theircontents, but tanks of non-metallic material should not be usedin conjunction with combustible liquids. They must be equippedwith a level indicator and with a safeguard against overfilling. Inthe design of tanks, consideration should be given on how todeal with any emissions during loading and unloading. Clearidentification of the hose connections, pumps etc., associatedwith the respective tanks, must be provided and adequatelighting must be provided in cases of night-time operation.

34



Tank farm arrangements Tanks must be installed in a liquid-tight bund with sufficientcorrosion resistance against the stored liquids. The bund musthave sufficient capacity to hold the contents of the largest tankplus a small safety margin. Depending on the fire fightingprovisions, adequate retention capacity should also be availablefor fire-fighting water.

Tank farm with retention facilities

Loading and unloading facilities Loading/unloading areas should be designed so that fire cannotspread. These should be in the open to provide naturalventilation. Leaks from loading/unloading, fire-fighting waterand rainwater from these areas must be retainable. The standardof the electric installations in tank farms, transfer facilities andpumping stations must comply with the recommendations givenin the section commencing page 61. Provision must be made toprevent electrostatic discharges while loading and unloading bymeans of earthing.

Fire protection In the event of a fire in a tank farm, the immediate goals are :

- Effective fighting of a spill or a pool fire in the bund;

- Protection of the tanks against excessive heat.

To achieve this, fixed systems may be required. For details,expert advice should be sought.

35


36


FORMULATION AND PACKING FACILITIES

Formulation of liquids 38Fire/explosion precautions 38

Electrical installations 38Electrostatic discharges 39Thermal decomposition 41

Industrial hygiene precautions 41Environmental protection 43

Formulation of solids 43Fire/explosion precautions 43

Preventive measures 44Protective measures 44Avoidance of thermal decomposition 44

Industrial hygiene precautions 46Environmental protection 47

Packing facilities 47Packaging material 48Layout of packing lines 49Packing line equipment 49

General 49Packing of liquids 51

Fire/explosion precautions 51Packing of solids 51

37


Formulation and packing facilitiesThe choice of formulation and packing equipment should berelated to the properties (physical and chemical) of thesubstances handled and reviewed whenever a new product isintroduced. A maintenance programme should be established tokeep the facilities in good working order.

Formulation of liquids

Liquid products, such as solutions and emulsifiableconcentrates, are usually formulated by mixing activeingredients, solvents, emulsifiers and other adjuvants in amixing tank. After mixing, the solution may be filtered and thentransferred to an intermediate storage tank prior to packing.Attention must be paid to hazards of the products handled andthe equipment must be designed accordingly.

Fire/explosion precautionsIf flammable liquids are used in formulation and packing plants,the possibility of build-up of an ignitable mixture of air andvapour exists. For this reason, all possible sources of ignitionmust be excluded from the area in which such activities takeplace (see section commencing page 61). In addition, inerting ofthe equipment or parts of it by nitrogen blanketing may need tobe considered where products with a particularly high fire-riskare handled.

Electrical installationsAll electrical installations (e.g. electrical motors, switches,control panels, lighting, power plugs and sockets, wiring, etc.,)must be designed in accordance with the electrical zoneclassification (see section commencing page 61) and inaccordance with the electrical code of the country. Temporaryelectrical installations should be avoided. Loose flexibleelectrical leads are prohibited. Only those electrical installationsnecessary for the operation should be located in rooms whereproducts are handled.

38


Install electrical equipment correctly

Electrostatic dischargesMeasures must be taken to prevent build-up of electrostaticcharges anywhere in the formulation area.

In formulation plants, build-up of hazardous electrostaticcharges is likely to occur during the following operations :

39


- Conveying of non-conductive liquids through pipes. To minimise the risk of spark discharges, conductive andearthed piping must be used. The conductivity of the pipingand proper earthing must be routinely checked. Filling oftanks and vessels should be via pipe work that extends closeto the bottom or is directed against the wall. In the event ofbelow-level filling, precautions should be taken againstsyphoning or sucking back from the tank;

Minimise splashing to avoid electrostatic sparks. Feed liquids below the level to avoid electrostatic discharges

- Filling and emptying of drums with flammable liquids. To avoid electrostatic discharges, drum pumps and drumsmust be of conductive material and earthed (check for rust,lacquer, paint and other insulating materials);

- Loading of powders into vessels containing flammable liquids. This operation exhibits a particular risk because of thepresence of both ignitable vapours and ignitable dusts(hybrid mixtures);Direct loading of powders through openings is onlypermitted from earthed conductive containers, via earthedconductive funnels and in small portions;Larger volumes and powders being loaded from non-conductive containers (e.g. plastic bags) should be loadedthrough an airlock device;

40

Formulation and packing facilities


- General measures All permanently installed equipment must be properlyearthed and routinely checked. Operators working in riskareas should wear safety shoes with electrostaticallyconductive soles.

Thermal decompositionHot water baths and hot water or steam heating jackets onmixing tanks must be equipped with a temperature limitationdevice and a high-temperature alarm to prevent possibledecomposition and run-away reaction of thermally unstablecompounds. This also prevents uncontrolled release of solvents.

Industrial hygiene precautionsDuring crop protection product formulation and packing,industrial hygiene is particularly important because of thetoxicity of many of the products. Therefore, the equipment usedmust be designed so that exposure of personnel working in thearea is reduced to a minimum.

The following equipment-related points should be observed :

41

Proper earthing avoidselectrostatic ignitions

Safe feeding of powders by means of anairlock device


- Formulation must be carried out in contained systems.Remote operation should be considered in areas where plantoperators are at risk of exposure to harmful chemicals;

- Where open handling is unavoidable, the emerging vapoursor dusts must be removed by means of an efficient localsource ventilation. To be effective, the intake to the ventilationsystem must be placed as close as possible to the source ofrelease and the capture velocity must be at least 0,5 m/sec;

Ventilation must be placed as close as possible to the source of vapour or dust

- Enclosure within a ventilated hood should be considered,when several contamination sources are close together anddifficult to equip with individual extraction nozzles;

- The equipment should be designed to allow cleaningwithout entry into tanks and vessels;

- Splash guards and catch trays must be installed in locationswhere splashes and occasional leaks are to be expected (e.g.pump seals);

- Permanent pipelines should be used in preference to inter-changeable hoses. Where manifold connections are used,

42



self-sealing couplings may be fitted to prevent spills whendisconnecting.

Environmental protectionTo contain any environmental effects and to minimise waste, thefollowing points must be considered in the design of theequipment:

- Provisions must be made to rinse empty active ingredientdrums with the solvent used for formulation and to recyclethe rinsings into the formulation;

- The area in which the processing vessels are installed shouldbe bunded;

- Vessels must be equipped with a safeguard against over-filling;

- Consideration should be given to the purification of airextracted by exhaust systems. Scrubbing, adsorption (e.g. onactivated carbon) or incineration may be required when toxicor odorous compounds are handled.

For more information, see section 6 commencing page 72.

Formulation of solids

Powder products, such as wettable powders or dusts, are usuallyformulated by blending and subsequent grinding of activeingredients, carriers and other formulation ingredients. Usually,these raw materials are solid; however, if liquid ingredients areused, they must be adsorbed on carrier materials with highadsorptive power.

Fire/explosion precautions The milling system is the most critical part of the powderprocessing plant as far as dust explosions are concerned.

The choice of preventive and protective measures is dependenton the product, the equipment, and possibly also on locallegislation. Specialist advice must be sought.

Prevention of dust explosions, or protection in order to minimisethe impact of a possible explosion, is primarily a matter ofproper equipment design and can be achieved as follows :

43


Preventive measures- Inerting :

To reduce the oxygen content, nitrogen blanketing is themost reliable method of preventing an explosion. However,this requires a closed-circuit grinding system withdependable oxygen monitoring;

- Exclusion of ignition sources : To reduce risk of generation of mechanical sparks, grindingand high-speed mixing plants must be equipped with trampmetal separating devices; To avoid risk of electrostatic discharges all conductive partswithin the equipment must be earthed, especially thesupport cages of filter bags which are high-risk areas forelectrostatic discharges in milling or mixing systems.

Protective measures The following protective measures can be used :

- Explosion-pressure shock-proof construction, separatedfrom equipment not at risk to dust explosions, by means ofquick shut-off devices;

- Installation of an explosion suppression system usuallybased on explosion pressure detection and instant dischargeof suppressant chemicals into the emerging explosion;

- Explosion-relief venting, for example by means of burstingmembranes. This may be a low cost means of controllingdust explosions, but is also the least desirable for cropprotection products due to the risk of environmentalpollution which could be caused by the release of possiblylarge volumes of crop protection products. This optionshould only be selected after careful consideration of safetyand environmental risks.

Such systems must be regularly checked and maintained.

Avoidance of thermal decompositionEquipment parts which, when running hot, can cause localoverheating in the product. This can lead to exothermicdecomposition, possibly followed by a smouldering fire orthermal explosion. Preventive devices should be installed todetect decomposition, sound an alarm and possibly triggerautomatic emergency measures (e.g. flooding). Products known

44



to be sensitive to thermal decomposition, must be quarantinedbefore they are moved to the warehouse.

Dust explosion suppression system

45

10 20 30 40 50

1

2

3

Suppressedexplosion

Normalexplosion

Pres

sure

(ba

r)

Time (milliseconds)

Start of explosion

Detector

Suppressor

Extinguisher


Industrial hygiene precautionsAs in formulation of liquids, skin contact and inhalation duringpowder formulation are the most common routes of exposure forplant operators. Ingestion is of lesser importance in this context.

Control of dust is the single most important industrial hygienemeasure in powder formulation plants. In particular, the followingpoints are to be observed :

- Open handling of dust should be avoided as much as possible;

- The entire formulation unit must be dust-tight;

- Hoppers, filter boxes and other equipment installed after thegrinder must be under slight negative pressure;

- Efficient source ventilation must be provided;

- Powder charging positions must be equipped withventilated hoods and properly designed suction nozzles;

- Air must be squeezed out from empty bags within the rangeof the source ventilation. For transport to the disposal site,they must be packed into tightly sealing outer bags or otherclosed containers. To reduce the volume, a ventilated bagcompacting unit can be used;

- Shaft seals should preferably be purged by air or, dependingon properties, nitrogen to prevent dust leakage;

Avoid leaking of dust by purging

46


Purgingair/nitrogen


- An industrial vacuum cleaner with suitable filters should beavailable.

Noise is another relevant industrial hygiene factor in powderformulation plants. If grinding units or blowers cannot beinstalled in a separate room, they should be located in a sound-proof enclosure.

Environmental protection The most common potential for environmental contaminationduring formulation of powders arises from possible emission oraccidental spreading of dust.

To prevent uncontrolled emissions of dust from sourceventilation systems, the extracted air must be directed throughan effective dust filter before its release to the atmosphere.Residues collected in the filter should ideally be recycled back tothe product concerned. However, cross-contamination must beavoided. Consideration should be given to monitoring thedifferential pressure in the filters to detect possible failures.

In special cases, a wet scrubber or other high-performancecleaning equipment may be necessary in addition to the dryfilter system.

For more information, see section 6 commencing page 72.

Packing facilities

Packing of crop protection products, because of the risk ofoperator contact, is potentially one of the most hazardousoperations in a crop protection product formulation and packingplant. Safe packing can best be achieved by ensuring that :

- Good housekeeping standards are maintained;

- Packaging materials are fit for the purpose;

- Packing lines are laid out to allow the free flow of materials,avoiding congestion;

- Equipment is designed for safe operation;

- Containment is provided for spillage, splashing or drips;

- Source ventilation is provided to control vapour and/ordusts;

47


- Due consideration is given to the flammability of liquids orsolids;

- Work instructions and procedures are available and adheredto;

- Operators are fully trained for the task;

- The necessary personal protective equipment is worn byoperators;

- Containers are securely closed after filling;

- All containers are clearly labelled or marked when they leavethe packing line;

- Safe stacking heights for packed products are adhered to.

Manual decanting from one container to another is notrecommended.

Packaging materialsContainers, outer packaging and labels must conform to nationaland international regulations (e.g. FAO Guidelines for thePackaging of Pesticides, UN Recommendations on the transportof dangerous goods, CropLife International Recommendations forone-way agrochemical packaging design criteria for liquids andsolids.

Only packaging materials which have been tested to becompatible with the product, are easily emptied and cleaned, andare compatible with filling and packing equipment, must be used.

Quality control procedures must be in place to ensure that out-of-specification packaging materials are not admitted to thepacking lines. Procedures must also be in place to test theintegrity of closures after capping or sealing.

Advice on quality control of packaging materials is laid down inthe CropLife International Guidelines for the quality control ofcrop protection products.

Labels must be correctly positioned and firmly affixed or printedon containers, and must not become detached or illegible,particulary when wet or in contact with product.

48



Layout of packing linesPacking lines must be designed to ensure the smooth flow ofempty-packaging components, product supply, filled and sealedcontainers, and finished, packed products.

A clear working zone for the operators must be provided andareas of congestion should be avoided. Adequate access formaintenance of equipment must be provided.

Segregation or physical separation of packing lines handlingdissimilar products (e.g. herbicides and insecticides), should beconsidered to avoid cross-contamination.

Pallet patterns and safe stacking heights for all finished, packedproducts must be established and adhered to.

Pallet loads can be secured for example by strap banding orstretch film.

If heat shrinking is used, specific safety measures (e.g. avoidanceof direct ignition or overheating, quarantine before moving tothe warehouse) must be taken. The use of heat shrink deviceswith open flames is not recommended.

Packing line equipment

General The zone around any filling and capping or sealing equipmentshould be enclosed to prevent exposure to operators and must beprovided with local exhaust ventilation for vapour or dustremoval, having a minimum capture velocity of 0,5 m/sec at allopenings. Air flows must be directed away from operators’breathing zone.

All filling machines should be fitted with an automatic closuredevice to shut off product supply when de-energised.Construction materials must be compatible with the productshandled.

All rotating or moving parts of filling and packing machinesmust have protective guards to prevent fingers or clothing beingcaught.

49


Protect operators from moving parts

Automated packing lines should be provided with breaks inconveyor belts to prevent the spread of spillage.

Prevent spread of spillage

50



Packing of liquids Packs must not be completely filled. Allowance for expansionmust be provided according to national or international rules.Filling equipment must be designed to avoid splashing orfoaming (e.g. by using below-neck or sub-surface fillingtechniques). Drip removal or collection must also be provided toprevent contamination of the outer surfaces of the pack.

Equipment must be maintained free from leaks and catch traysmust be provided to cope with leaking or upset containers.

Fire/explosion precautions Where flammable products are to be filled, all possible sources ofignition must be excluded from the filling and capping or sealingzone and all electrical equipment must comply with theelectrical zoning classification.

In situations where heat sealing of containers filled with solvent-based products with low flashpoint is involved, the followingadvice should be followed :

- Where induction sealing is employed, the unit should beinstalled away from the filling and capping area and must beprovided with protective measures to ensure overheating ofthe seal is not possible;

- Where hot plate sealing is employed, good source ventilationshould be installed.

In order to avoid electrostatic discharges, in addition to theadvice given in the section commencing page 61, earthing of allmetal containers must be assured (e.g. by the use of an earthedmetal conveyor belt).

Packing of solids Equipment used for the packing of solids must be maintainedfree from leaks, and all surfaces in the filling and sealing areamust be designed to avoid accumulation of dust deposits and foreasy cleaning.

Advice given on formulation of solids (see section commencingpage 43) must be followed for the choice of equipment in thefilling and sealing area.

51


52


OCCUPATIONAL HEALTH,HYGIENE, PERSONAL SAFETYHousekeeping 54Personal protective equipment 55

Coveralls 55Eye protection 55Foot protection 55Hand protection 55Head protection 55Respiratory equipment 55Responsibilities 56

Amenities-laundry 56Medical supervision 57

Pre-employment examination andbiological monitoring 58Hygiene monitoring 58First Aid - emergencies 59

FIRE/EXPLOSION PREVENTIONAND EMERGENCY PLANNINGAvoidance of ignition sources 61

Hazardous areas (zoning) 61Specific measures 61

Smoking 61Hot surfaces 62Mechanically generated sparks 62Electrical safety 62Fork-lift trucks 63Auxiliary equipment 63Non-routine activities 64

Equipment for detection and fire fighting 64Fire detection, fire alarms 64Mobile fire extinguishers 65Hydrants, hose lines 66Preventive maintenance 66

Emergency planning 66Equipment location plan 67Training, fire drills 67Spillages 67Clean-up 68Equipment to deal with spills 69

53


Occupational health, hygiene, personal safety

The key preventive measure from the health and safetystandpoint is to avoid exposure of personnel to the products. Inaddition to the measuring already described, the followinghygiene and health measures must be taken into account.

Housekeeping

The term «housekeeping» in this context refers to theorganisation and regulation of plant activities to ensure:

- An orderly, safe and efficient use of plant working space;

- The maintenance of a clean and safe working environment;

- The safe disposal of waste materials.

Good housekeeping goes hand in hand with a safe and high-quality operation. Poor housekeeping is not only an indication ofpoor work attitude, it provides the potential for an unsafeoperation.

Poor housekeeping is a potential danger for staff, environment and product quality

54


Good standards of hygiene should be maintained throughsystematic tidying of the site, and cleaning of floors andequipment. Spillages must be dealt with immediately (seesection commencing page 61).

Personal protective equipment

Depending on the degree of risk, use of the following personalprotective equipment may be required :

- Coveralls Employees must be provided with coveralls (preferablycotton, covering body, arms and legs). Sufficient spare setsshould be available to change any time the coverall iscontaminated and to allow regular washing;

For specific tasks, extra protection should be provided by the use of rubber or plastic aprons, or in extreme cases, by fullprotective suits;

- Eye protection Where indicated, employees must wear eye protection as asafeguard from splashes or dust (e.g. safety spectacles,goggles or face shield);

- Foot protection Safety shoes or boots with protective toecaps must be wornby all employees in a formulation and packing plant toprotect against any contact with the product and from fallingobjects;

- Hand protectionWhere specified, chemically resistant gloves must be used tohandle crop protection products (PVC and nitrile rubber arethe most appropriate);

- Head protection Employees must wear a helmet wherever there is risk fromoverhead hazards;

- Respiratory equipment Where the properties of the products to be handled indicate,employees must wear a dust mask or a vapour absorptionmask;

In extreme conditions, the wearing of self-contained breathing equipment may be necessary. This should be anexception and only for limited periods. Employees who usethis equipment must be physically capable and fully trained;

55


The design of the equipment and the type of operation being carried out willdetermine which items of the illustration must be worn

- Responsibilities Each employee must be responsible for cleanliness andphysical condition of his own personal protective equipment.Protective equipment must be decontaminated and cleanedafter use. Any fault or damage must be reported to thesupervisor and corrected.

Amenities-laundry

Eating, drinking and smoking must be prohibited in theworkplace. A separate facility, maintained to a high level ofcleanliness, should be provided to enable drinks and meals to betaken. The facility must include hand washing facilities. Amandatory procedure must be established to ensure the washingof hands and face before eating, drinking or smoking.

56


Protective helmet or cloth cap

Eye protection (safety spectacles,goggles or face shield)

Dust or vapour mask

One-piece worksuit with closelyfitting trouser bottoms

Rubber or plastic gloves orgauntlets

Rubber or plastic apron

Workboots with protective toecaps


Changing and washing facilities must be provided. They shouldinclude separate lockers for work clothes and for personalclothes, separated by showers, to avoid contamination of thepersonal clothes. Showers should be cleaned every day.

Taking a shower at the end of the work period is recommendedand mandatory after any accidental contamination.

Provide showers and separate lockers

Working clothes must be changed for clean clothes wheneverthey are contaminated. Laundry must not be taken home.

If laundering is carried out on the factory site, considerationshould be given to directing contaminated wash water to thewaste water treatment plant.

If the laundry is handled by an outside contractor, only anapproved contract service should be employed which must beable to cope with washing of chemically soiled clothing.

Medical Supervision

Medical examinations must be provided for all operators (thismay be a legal requirement).

57


Examinations should be conducted on a periodic basis. Aphysician, knowing the plant and all the products handled, mustbe available for these medical examinations and any follow-upin case of continuing health problems of individuals.

Pre-employment examination and biological monitoring An initial medical examination must be conducted on allpermanent and contract/temporary staff before commencingwork with crop protection products.

In cases of possible exposure to cholinesterase inhibitors, suchas organophosphorus compounds, the base-line bloodcholinesterase level for each staff member must be established.

Subsequent monitoring will enable recommendations for jobrotation when low levels are detected, thus avoiding furtherexposure.

Further biological monitoring, e.g. of blood, urine or skincondition related to the substances being handled, can also beemployed. Specialist advice must be sought before setting upany monitoring programme and in all cases results of suchmonitoring must be interpreted by a physician.

However, biological monitoring should be considered as asecondary means of monitoring as it will always beretrospective.

Hygiene monitoringPotential hazards to health at work can be monitored bymeasuring the concentration of hazardous dust, vapour or gas inthe workplace, particularly within the breathing zone ofoperators. This can be achieved with static, spot or personalmonitoring equipment.

These types of measurements should be supervised andinterpreted by an expert hygienist.

58



Sampling head-positioned within breathing zone

First aid - emergencies An arrangement should be in place with a doctor or hospitalwhich must be well informed about the products handled in theplant. The formulation and packing plant must be equipped forhandling accidents and sufficient employees must be trained forfirst aid and emergency actions.

For first aid, the following should be available in clearlyindicated locations :

- Emergency shower and eye wash facilities;

- Safety Data Sheets (SDS);

- Emergency telephone numbers connected to permanent medical assistance (e.g. hospital);

- Updated stock of antidotes for the crop protection products handled in the plant;

- Medical oxygen supply.

59

Breathing zone

Sample head

Pump


Emergency shower - accessible and easy to use

In cases of accidental exposure and of suspected exposure to aproduct, the recommendations of the SDS must be followed.

If medical support is necessary, the SDS or the product labelshould be sent with the person affected to the doctor or hospital.

See also : CropLife International Guidelines for emergencymeasures in case of crop protection product poisoning.

60


Squeeze-operated eye-wash bottle -change water frequently

Provide emergency telephonenumbers

Doctor HospitalFirePolice


Fire/explosion prevention and emergency planning

Avoidance of ignition sources

Hazardous areas (zoning) The extent of safety measures required to avoid ignition sourcesdepends on the area in which the operation takes place. As far asthe likely presence of ignitable gas/air or vapour/air mixtures isconcerned, the following zones can be defined:

Zone 0 : Areas in which an explosive atmosphere is continuallypresent or present for long periods of time. These conditionsnormally prevail only within formulation or packing equipmentareas.

Zone 1 : Areas in which an explosive atmosphere is likely tooccur during normal operation. These conditions can prevail inthe immediate vicinity of Zone 0 (e.g., around charging anddischarging openings).

Zone 2 : Areas in which an explosive atmosphere is unlikely tooccur during normal operation and, if it occurs, will only existfor a short time. These conditions can, among others, prevail inareas surrounding Zones 0 and 1.

Specific measuresSome advice on design features to avoid ignition sources is givenfor formulation and packing facilities (see section 4 commencingpage 38). In addition, the following points should be observed :

SmokingIt is recommended that the full site is declared non-smokingexcept for nominated areas or rooms.

However, smoking must be prohibited in all operation-relatedareas of the site. Visitors and contractors should not be allowedto enter the plant unaccompanied and they must be informedabout no smoking rules.

In rooms where smoking is expressly allowed, metal or glassashtrays must be provided and routinely emptied.

61


Hot surfacesArrangements must ensure that heat-sensitive products do notcome into contact with hot surfaces (e.g. non-insulated steampipes, dryers or overheated motors, bearings or stuffing boxes).The following measures may be considered :

- Air or nitrogen purging of shaft bearings;

- General avoidance of dust deposits;

- Insulation of steam pipes.

Mechanically generated sparksIn order to minimise risk of mechanically generated sparks :

- Eliminate tramp metal from ingredients before they are fedinto powder processing equipment (e.g. by means ofmagnetic or inductive metal separators or screens);

- Check rotating parts regularly for clearance, mechanicalfriction and cleanliness;

- Choose equipment with low relative velocity of movingparts.

Electrical safety All electrical equipment and wiring must be installed andmaintained by a qualified electrician, and must be positioned soas to avoid accidental damage. Adequate earthing and overloadprotection must be provided.

All mobile electrical equipment (e.g. power tools, portablepumps, cooling fans and equipment borrowed from other areas)must be approved from a safety point of view.

Depending on the materials handled, the standard of theformulation equipment used and the degree of risk, certain areasof the formulation and packing plant may be classified ashazardous areas (i.e., Zone 0, 1 or 2 respectively). Accordingly,part or all of the electrical equipment used may have to be offlame-proof or explosion-proof standard. Guidance regardingthe suitability of electrical equipment for such zones may beobtained from either local electrical codes or insurancecompanies. In areas where the creation of explosive dust/air

62



mixtures is possible (outside the equipment), dust-proof fittingsshould be provided. In all other areas, this is not normallyrequired, but water-tight fittings are recommended.

In order to reduce the high cost of explosion-proof installations,it is recommended to locate the switchboard for equipment andlighting in a separate room outside the hazardous area.

Fork-lift trucksOnly certified flame-proof fork-lift trucks should be used inhazardous areas (Zones 0 to 2). Non-protected fork-lift trucksmay exceptionally enter Zone 2 for short periods, providedabsence of an explosive atmosphere can be guaranteed (e.g. bychecking with an explosimeter or similar device).

Auxiliary equipment The following equipment must not be used in hazardous areasdefined as Zone 0 or 1 :

- Petrol or gas-driven fork-lift trucks;

- Electrical dryers;

- Shrink wrapping equipment with open ignition sources;

- Battery charging stations.

Keep battery charging facilities away from stored goods

63


Ideally battery chargers or shrink wrappers should bepositioned outside or in a separate well-ventilated room.

Non-routine activities Non-routine activities such as maintenance work and plantclean-outs which can produce ignition sources (e.g. welding,drilling, etc.,) must be authorised in writing. The written workpermit must :

- Specify how the equipment has been isolated;

- Give directions to clear the work area of combustible materials;

- Warn of possible dangers and indicate precautions to ensure that the job can be done safely;

- Record the persons assigned to the job;

- State the period of validity.

Written permits are needed for all non-routine jobs

Equipment for detection and fire-fighting

Fire detection, fire alarms Since fire-fighting is most effective in the early stages of a fire,early detection and alarms are essential.

For fast response to the outbreak of a fire, formulation andpacking plants must be equipped with an internally audiblealarm and must have means to call the fire service (e.g. telephoneor push button).

64



Automatic alarm systems are particularly effective, if theresponse time of the fire service receiving the alarm is less than15 minutes. These systems must be properly maintained andregularly checked.

Sprinkler systems must always trigger an alarm when activated(with sprinklers installed, no other fire detection system isnormally required).

Mobile fire extinguishers Mobile or portable fire extinguishers are the first available meansto fight an emerging fire. Their quantity, size and type should bediscussed with the local fire service. These must be positioned ineasily accessible places, which must be marked with a prominentsign and kept clear.

Position fire extinguishers close to the exit and keep clear

Dry powder or CO2 extinguishers are effective for solvent fires.For electrical installations, CO2 extinguishers are recommendedand water must not be used.

65


Checking and maintenance of fire extinguishers must be inaccordance with the local regulations. Partly used extinguishersmust be exchanged.

Hydrants, hose lines Where hose reels are used, it must be possible to reach any partof the plant area with the discharge from at least one hose line.Internal hose reel cabinets are recommended, although outsidehydrants may be sufficient. Water nozzles should be designedfor spray as well as full jet.

Location, spacing and design of hydrants should be agreed withthe local fire service to ensure compatibility of equipment(identical hose couplings, etc.,). Where large amounts offlammable crop protection products are stored, it may beadvantageous to stock foam concentrate and foam-makingequipment for use by the local fire brigade. Where plantpersonnel are required to use foam-making equipment, specialtraining will be needed. Alcohol resistant foam is required forwater miscible solvents or emulsifiable concentrates. Foamconcentrates may deteriorate with age and must be checked forquality according to manufacturer’s instructions.

Preventive maintenance All important safety equipment of the plant such as firedetection, alarm and extinguishing systems, automaticallyclosing fire doors or lightening protection systems must beregularly maintained and checked by trained personnel.

Emergency planning

To reduce the potential for injury to people and damage to theenvironment, a fire emergency plan must be established and allstaff members must be trained in practising the plan. Anyemergency plan should include collaboration and agreementwith the local fire service. This is not only to discuss the fire-fighting arrangements, but also to consider the consequences ofsmoke or fumes and the possible escape of fire-fighting water.

In view of the possible consequences of escaping fire-fightingwater which cannot be contained, it is also important to get prioragreement as to the circumstances in which fire-fighting shouldbe ceased and who will make the decision.

66



The basis of an effective emergency fire-plan is an equipmentlocation plan, training and fire drills.

The emergency plan must show where to get help

Equipment location planA plan showing the position of all fire-fighting equipment andall protective devices on site should be displayed in at least twoeasily accessible places.

Training, fire drills All personnel should be trained in the use of the types of fire-fighting equipment present on site. Fire emergency plans must bepractised regularly to familiarise the personnel while at the sametime checking the equipment. More details on fire-fighting practicesand the clean-up procedures after a fire are given in the CropLifeInternational Guidelines for safe warehousing of pesticides.

Spillages All spillages must be reported to a responsible person and dealt

67


with promptly. Spilled product must not be allowed toaccumulate or spread about.

Clean-up Powders and granules should be removed, preferably using anindustrial-quality vacuum cleaner fitted with both a primaryand secondary filter. If a brush and shovel are used, reduceairborne dust by first spreading damp sand on the spillage.

Spilled liquid products should be absorbed onto absorbentmaterial before being swept up and transferred into a sealedcontainer for disposal.

Water must not be used to wash away spills, pick up liquids with absorbent materials

68



After this first cleaning of the floor, the remaining contaminatedsurface can be carefully washed with a minimum of water. Donot let water run off, but soak up with more absorbent material.

Equipment to deal with spills The following equipment should be available and placed on apallet or cart kept in a readily accessible location and markedwith a prominent sign :

- 1 drum with granular clay or other absorbent material;

- Broom, shovel and rubber wiper;

- 5 empty large heavy-duty plastic bags;

- 2 empty open head drums;

- Optionally, sand bags (enough to build a protective dam);

- Gloves, eye protection.

Keep clean-up equipment for spills handy

Where outside drains exist, plugs or plastic bags filled with sandand water (including anti-freeze where necessary) must bepositioned close to the drains to be able to stop them up.

69


70


ENVIRONMENTAL PROTECTION

Avoidance and minimisation 72

Avoidance 73

Recycling (recovery, re-use) 74

Avoidance of further dilution 75

Treatment and disposal 76

Treatment of contaminated air 76

Treatment of contaminated water 76

Physical treatment 77

Physical separation 77

Solar evaporation 77

Absorption 77

Chemical treatment 77

Biological treatment 78

Incineration 78

Treatment and disposal of contaminated waste 78

Disposal options for specific waste types 80

Non-contaminated waste 80

Lightly contaminated waste 80

Hazardous waste 82

Documentation and records 82

Waste disposal contractors 83

Transport 83

71


Environmental protection

Potential risks to the environment can result from theuncontrolled release of dangerous products (see page 14). Thesereleases can occur during normal operation of the plant oraccidentally in the following forms :

- Contaminated air (e.g. from source ventilation);

- Contaminated water (e.g. from cleaning operations);

- Contaminated waste (e.g. off-specification products, filtration residues, waste from spillages).

Close attention must be paid to avoid or reduce the generation ofemissions and waste. This will not only reduce the costs fortreatment but can save valuable product.

Waste disposal regulations and emission standards have been setby authorities in many countries. Where waste disposal andemissions are not legislated, their acceptability needs to beevaluated on a case-by-case basis.

Options for possible solutions are :

- avoidance and minimisation

and

- treatment and disposal.

Avoidance and minimisation

Most of the measures are described under the sub-headings

- Avoidance;

- Recycling (recovery, re-use);

- Avoidance of further dilution.

These apply to environmental protection as well as to safety,occupational health and hygiene.

72


Decision chart for environmental protection options

Avoidance Some typical examples are :

- All equipment designed as contained system and for easycleaning;

- All equipment maintained in good operational condition toavoid leaking or air infiltration;

73

CONTAMINATED AIRCONTAMINATED WATERCONTAMINATED WASTE

Is avoidancepossible?

Can dilution beavoided?

Is a pre-treatment(concentration)

possible?

Is recycling (recovery,

re-use) possible?

AVOID

RECYCLE

AVOIDANCE OFFURTHER DILUTION

PRE-TREATCONCENTRATE

CHOOSE THE APPROPRIATETREATMENT OPTION

NO

NO

NO

NO

YES

YES

YES

YES


- Avoidance of contaminated packaging materials :

• by bulk delivery of ingredients in returnable containers;

• by avoidance of intermediate filling between the formulation and packing stages;

- Avoidance of waste from cleaning operations

• by using long single-product production runs;

• by optimising the sequence of products on the same production line;

- Avoidance of off-specification products, old stock andspillages by complying with the recommendations forquality control and safe handling given in these and otherCropLife International Guidelines (see page 106).

Recycling (recovery, re-use) Examples for recovery and re-use are :

- The use of individual filter systems for each production lineto enable recycling of filter residues;

- Use of liners for solid materials supplied in drums. Theremoval of the contaminated liner will normally leave theouter container free from contamination;

- Re-use of drums, in which active ingredients or othermaterials have been supplied, for compatible finished-products;

Rinse empty drums

74



- Rinsing of empty drums with compatible solvents which canbe recycled in formulation;

- Collection and recycle of materials recovered fromformulation and packing equipment clean-out.

In order to avoid cross-contamination resulting from inadequaterecycling and re-use, the advice given in the CropLifeInternational Guidelines for quality control of crop protectionproducts, must be followed.

Avoidance of further dilutionIn general, the higher the concentration of a hazardouscomponent, the more effectively and less expensively it can betreated and destroyed. Therefore, uncontrolled dilution ofcontaminated air or water should be avoided.

Typical examples to avoid uncontrolled dilution are :

- Well-designed, high-performance source ventilation;

- Separate air extraction systems for source ventilation and general ventilation;

- Clearly defined cleaning procedures and devices to keep the amounts of waste water to a minimum;

Do not use uncontrolled amounts of water

75


- Use of good quality adsorbent or absorbent materials to dealwith liquid spillages (not sand). If the waste disposal optionis incineration, it is reasonable to use a combustibleadsorption or absorption material.

Treatment and disposal

Management must ensure that procedures for treatment anddisposal exist and are followed. It is recommended to seekspecialist advice wherever local expertise is not available.

Treatment of contaminated air Depending on the components handled, the equipment and theoperational procedure used, the following options for thetreatment of contaminated air before emission can be chosen :

- Filtration of solid materials by dust separators;

- Absorption of solid materials or gases/vapours in scrubbingtowers;

- Adsorption of gases/vapours in adsorption towers (e.g.filled with activated carbon).

In special cases (e.g. highly active or odorous products), it maybe necessary to combine two of the options (e.g. filter system andscrubber).

Treatment of contaminated water The following sources of contaminated water should beconsidered :

- Water used to clean equipment (if not re-usable);

- Floor washings, especially after spillages;

- Rain water after spillages;

76


Note : Waste water dilution may be necessary forbiological waste water treatment


- Washing water from cleaning of filter cloths;

- Waste water from the laboratory;

- Water from scrubbers.

Physical treatment Physical pre-treatment methods are used to increase theconcentration of environmentally hazardous components, thusreducing the volumes for ultimate disposal.

In all cases the waste water released after treatment must complywith local legal requirements.

Physical separation Separation of suspended fine particles can be achieved bymethods such as sedimentation, filtration, centrifugation orflotation. Flocculation by the addition of suitable chemicals andfilter aids can improve the separating operation.

Solar evaporation In certain circumstances, solar evaporation can be used toconcentrate contaminated waste water in an imperviousevaporation pond. This method is suitable for relatively smallvolumes in hot climates. In wet regions, roofing of the pond isrequired.

Depending on the nature of the crop protection productcontained in the waste water, undesirable odours can be emittedwith this method.

Absorption The process utilises the capacity of a suitable absorbent materialsuch as activated carbon to absorb dissolved organic materials(e.g. crop protection product active ingredients, solvents, dyes,etc.,).

Spent activated carbon loaded with hazardous components mustbe disposed of safely, preferably by incineration.

Chemical treatment In special cases a chemical treatment such as hydrolysis oroxidation may be of advantage. As the degree of degradation ofindividual compounds varies considerably, chemical treatment

77


is normally combined with other methods (e.g. biologicaltreatment).

Biological treatment Biological treatment processes are based on the ability of micro-organisms to decompose or mineralise specific chemicalcomponents. The process operates under well-controlledconditions but is particularly sensitive to changes in thecomposition of the contaminated water and to toxic effects onmicro-organisms. It may not be effective for all possiblecontaminants.

Sludges from the plant may be slightly contaminated with activeingredients and must be disposed of safely.

Depending on the situation, it may be necessary to combine twoor more of the above methods.

IncinerationWhere a high temperature incinerator is available, contaminatedwaste water may be safely disposed of by incineration togetherwith other waste. For economic reasons, the quantity should below and the concentration as high as possible. Refer to CropLifeInternational Guidelines on disposal of unwanted pesticide stocks.

Treatment and disposal of contaminated waste The following types and source of waste would normally bedealt with within a formulation and packing plant :

- Non-contaminated waste (e.g. site rubbish, clean cardboard, plastic, wood, paper, etc.,);

- Lightly contaminated waste (e.g. contaminated packaging materials and other materialswith low contents of active ingredients or other hazardouscomponents like sludges from waste water treatment plant);

- Hazardous waste (e.g. off-specification products, old stocks, filtration residues,waste from spillages, etc.,).

78



A system based on clearly defined procedures andresponsibilities for the collection, assembly, storage, treatment,packing, labelling and transport of waste must be established oneach manufacturing site.

All types of waste must be handled safely according to theirinherent hazards during the different steps of handling such ascollection, pre-treatment (e.g. compacting, washing, crushing,shredding), storage, transport and disposal, following therecommendations laid down in these Guidelines and otherrelevant CropLife International Guidelines (see page 106).

In order to optimise waste handling and disposal, it isrecommended to install the following equipment :

- Waste compactor To reduce the volume of low-density waste and overpack tominimise dust exposure;

- Waste shredder * To make plastic containers unusable and reduce their volume;

- Drum crusher *To make drums unusable and reduce their volume;

Drum Crusher

79


- Where no drum crusher or shredder is available, containerswhich are not re-used or re-conditioned, must be madeunusable by puncturing; *

- De-watering devices such as filter-presses, sleeve filters orair-drying beds for sludges or slurries from waste watertreatment before disposal.

Disposal options for specific waste types

Non-contaminated waste This should be disposed of according to the local regulations forhousehold waste.

Lightly contaminated waste If waste incineration is available, this is the preferred option forthese types of waste, especially combustible material (e.g. bagsand plastic containers).

The secondary option for disposal is a secure, licensed andapproved landfill site.

For steel drums, the different options of the steel drum disposaldecision tree (see illustration) should be chosen.

80


* Note : Provision must be made to avoid explosion,where containers potentially hold residues offlammable liquids.


Steel drum disposal decision tree

81

CROP PROTECTION PRODUCTDRUM

TRIPLE RINSEDRUM

RETURNDRUM

SEND FORRE-CONDITIONING

FOR NON-FOODUSE

Has drum beentriple rinsed?

Can drum be returnedto product supplier?

Is a reputable drumconditioner available?

Is drum suitable forre-conditioning?

Is a drum crusheravailable?

CRUSHDRUM

DESTROY DRUMSWITH PICK AXE

OR HAMMER ANDFLATTEN

Is steel smelteravailable?

SEND TOSMELTER

BURY IN ANAPPROVEDLOCATION

NOYES

YES NO

YES NO

YES NO

YES NO

YES NO


Hazardous waste The preferred option for this type of waste is high-temperatureincineration.

Crop protection products containing heavy metals such asmercury must not be incinerated. Advice in these circumstancesshould be sought from the Safety Data Sheet or from themanufacturer.

The publication CropLife International Disposal of unwantedpesticide stocks, guidance on the selection of practical options,gives detailed information and practical advice on the existingdisposal technologies under the following sub-headings :

- High-temperature incineration

- Cement kiln incineration

- Chemical treatment

- Long term storage

- Landfill (for incinerator ash and slag only)

In all cases, the disposal method chosen must comply with thelocal legal requirements.

Documentation and records Accurate documentation and records of waste and its disposalmust be established by the producer. The following informationshould be included :

- Process of origin

- Composition

- Quantity

- Labelling of packs for identification

- Dangerous goods labels for transport or handling

- Disposal details

82



Waste disposal contractorsOnly professional and reputable waste contractors must beemployed.

The producer of the waste is responsible for disposal. It isadvisable therefore, to assess the competence of the contractorand the suitability of the disposal method before use.

The disposal route for all waste consignments must be discussedand agreed with the contractor.

A certificate of disposal must be obtained from the contractor,stating that the waste has been disposed of in the agreed manner.Payment of invoices must be withheld until receipt of thecertificate of disposal.

Transport Strict attention must be applied to transport of waste fordisposal.

In many countries, waste vehicles must be registered andlicensed with the controlling authorities. In these instances thedisposer must ensure that only licensed vehicles are used.

Where these regulations do not exist, management must ensurethat the vehicles used are fully roadworthy, waste loads aresecure and not overloaded, and that a copy of the waste manifestand telephone contact numbers are available in case ofemergency.

All drivers must have received emergency safety training.Hazard warning signs must be prominently displayed onvehicles, where required by local regulations.

83


84


CHECKLIST 86

DEFINITIONS (GLOSSARY) 103

USEFUL REFERENCES 106

85


Checklist

This checklist has been written in such a way as to make it easyto complete. The answers will assist in the identification ofactions needed.

Hazards

N° QUESTIONS YES NO

1. Does the operation in the plant exhibit any hazard regarding :

• intoxication?• fire?• explosion (vapour, dust)?• auto-ignition?• exothermic decomposition?

2. Are there any potential ignition sources in the plant such as :

• hot surfaces?• naked flames?• mechanically generated sparks?• electrically generated sparks?• sparks from electrostatic discharges?

3. Is there a potential risk of environmental pollution by the release of crop protection products from the plant :

• via the liquid effluent?• via the exhaust air?• via the wastes?

86




4. Does the site manager have responsibility for the following aspects of his operation :

• safety and occupational health?• security of site and environmental

protection?• quality of products?• engineering and maintenance?• training and management of

personnel?• establishment of emergency

procedures?• relationship with external

organisations?

5. Which of the responsibilities are delegated?

6. Are you confident that all these delegates fully understand their responsibilities and are competent?

7. Is there a clear up-to-date organisation chart showing the defined management structure and communication lines in use?

87

Responsibility delegated :

……………………………………………

……………………………………………

……………………………………………

……………………………………………

Name (job function) of thedelegate :……………………………………………

……………………………………………

……………………………………………

……………………………………………



8. Do all members of the personnel have the adequate qualification, training and experience their job requires?

9. Are Safety Data Sheets available in the plant for the products and ingredients handled on the site for

• all hazardous products and ingredients?• all products and ingredients?

10. Are written documents available for all products, such as :

• specifications (for ingredients, packaging materials, finished products)?

• recipes?• analytical methods?• recording documents?

11. Does the plant keep formulation and packing quality control records?

12. Are there written procedures for :

• standard operation for formulation, packing and others?

• quality control?• engineering (maintenance,

modifications)?• fire prevention?• site security and emergency actions?

Are they available at the work place?

Does the plant manager audit on a regular basis that the procedures are being followed?

88

Checklist



13. Is there an annual training programme for :

• knowledge of product hazards?• fire fighting• safety and emergency procedures?

14. Is the site well-secured against trespassers by a controlled entry procedure?

Are outside gates locked during off-duty hours and is the site checked regularly?

15. Are there established relationships with the local community authorities?

16. Are the following local authorities for emergency fully aware of the nature of the products handled :

• fire service?• hospital or physician?

17. Are contractors employed for :

• formulation?• packing?• warehousing?• transport?• waste disposal?

If yes, have they been approved to be competent and reliable?

Has a responsible person been appointed to ensure that the details of the contract are followed?

89


Locations and Buildings


18. Does the site satisfy the requirements regarding distance to :

• schools, hospitals, shopping areas? • residential areas?• food processing or storage premises?• fresh water sources and surface water?

19. Does the site lie in an area which is prone to flooding? If so, are measures taken to prevent flooding?

20. Does the site satisfy the stipulation forsite access and for the access to the

individual buildings?

21. Are herbicides and plant growth regulators formulated and packed in areas separated from other products?

22. Is the powder processing equipment separated sufficiently from that for liquids?

23. Are all external walls sufficiently fire-resistant to avoid the spread of fire?

24. Are all floors impervious and easy to clean?

25. Do all internal division walls (fire-break walls) and doors in fire-break walls provide the necessary fire resistance?

90

Checklist



26. Do doors in fire break walls close automatically in case of fire?

27. Are the buildings adequately protected against lightening?

28. Are there fire retardants on electrical and other conduits going through fire break walls?

29. Is there a reliable public water network to provide sufficient water for fire-fighting?

If the public water is not sufficient, is there a water reservoir for fire- fighting on site?If so, what is its capacity? ………… m3

30. Are there provisions for the complete retention in every building :

• for product spills?• for fire-fighting water?

Is an additional external containment available?If so, what is its capacity? ………… m3

31. What is the total capacity of containment? ………… m3

Is it sufficient to contain the expected volume of fire-fighting water?

91



32. Are all rain waters from areas where products are handled, collected in a retention pit?

Is there is a drainage system? If so, can it be blocked conveniently if the water is contaminated?

33. If there should be existing drains in buildings :

• do they end in an interception pit? • are they connected with waterways or

public sewers?

34. Are all buildings well-ventilated and the lower vents above bunded height?

35. If the buildings are heated :

• is the heating source segregated from formulation, packing and storage areas?

• is direct heating of product avoided?• are the heating devices permanently

installed and portable heaters prohibited?

36. Are the buildings, and in particular the workplaces, properly lighted?

37. Are the facilities which generate excessive noise separated?

38. Are there at least two emergency exits in every manufacturing room?

39. Are all emergency exits clearly marked, of easy access and kept clear?

92

Checklist



40. If there are non-production facilities on the site, are they accommodated in separate buildings?

If not, are they segregated by division walls with at least 60 minutes fire-resistance time?

41. Are the tanks equipped with level indicators and safeguards to prevent over-filling?

42. Is a clear identification possible of hose connections, pumps, etc., associated with the tanks?

43. Are the tanks installed in a tight bund with sufficient capacity?

44. Is the unloading/loading area bunded and is the rainwater from this area retainable?

45. Are adequate provisions taken for fire fighting and to prevent electrostatic discharges in the tank area?

93


Facilities for formulation and packing


46. Are all ignition sources of the following types eliminated in areas where flammable products are openly handled :

• sparks from electrical installations?• sparks from electrostatic discharges?• open flames, hot surfaces?

47. Is there a safe system (e.g. airlock device) in place, which allows the safe charging of powders into flammableliquids?

48. Are the powders processing facilities equipped with the following dust explosion preventive/protective measures:

• tramp metal separation?• inerting?• explosion-pressure shock-proof

construction including quick shut-off devices?

• explosion suppression system?• explosion relief venting?

49. Are all dust explosion preventing and protecting devices kept in good working condition?

50. Are ventilation and air purification devices existing and kept in good working condition?

94

Checklist



51. Are charging and discharging positions equipped with well-ventilated hoods or effficient source ventilation?

52. Is formulation only carried out in contained systems and are the facilities well-ventilated during operation?

53. Is the extracted air from the powder processing units cleaned by effective cleaning equipment?

54. Are industrial vacuum cleaners, with suitable filters, available?

55. Are the formulation facilities dust-tight and free of leaks?

56. Are splash guards and catch trays installed in all places where splashes and leaks are to be expected?

57. Have heating devices (e.g. water baths, heating jackets) a reliable temperature limitation?

58. Are the packing materials and labels used tested to be of adequate quality and are they compatible with filling and packing equipment?

59. Are the packing facilities (e.g. filling and capping area) equipped with source ventilation?

95



60. Is the construction material of the equipment (e.g. hoses, gaskets, etc.,) compatible with the products handled?

61. Is the packing equipment leak-free and provided with catch trays?

62. Are the packing lines designed to provide adequate access for operators and maintenance work and a smooth flow of all components?

63. Are the filling machines fitted with an automatic closure device to shut off product supply when de-energised?

64. Is the equipment provided with all necessary protective guards for rotating or moving parts?

65. If heat shrinking is used, have the necessary safety measures been taken?



66. Are good housekeeping standards well-maintained and all areas kept clean and in good order?

67. Are the employees provided with suitable coveralls?

96

Checklist



68. Have the necessary arrangements for washing work clothes been made and is it forbidden to take contaminated laundry home?

69. Do employees wear personal protective equipment where specified, such as :

• safety shoes? • eye protection?• gloves?• helmets?• respiratory equipment?

70. Are the employees responsible for their own personal protective equipment and is cleaning after use well-organised?

71. Is eating, drinking and smoking forbidden within the working area and are there separate facilities for these activities?

72. Are changing and washing facilities with showers and separate lockers for clean clothes and work clothes available?

73. Is showering mandatory at the end of theworking day?

74. Are all amenities cleaned regularly?

75. Is there a pre-employment examination for all permanent and contract/temporary staff?

97



76. Is the health of all workers (including contractors) periodically monitored?

77. Where organophosphorus compounds are handled, is the blood cholinesterase level of each staff member involved monitored?

78. Are hygiene monitoring measurements done in the workplace and actions taken on the results?

79. Are records kept of all medical and hygiene supervision carried out?

80. Are adequate first-aid materials and facilities (e.g. emergency showers and eye-wash equipment) provided and are the staff familiar with their use?

81. Are the emergency telephone numbers available for the personnel?

82. Are some employees trained for first aid?

How many? ……………

83. Do you have an arrangement with a local hospital or a local doctor for permanent emergency assistance including an updated stock of antidotes for the crop protection products handled?

84. Do you provide this hospital or doctor with details on the nature of the products you handle?

98

Checklist


Fire prevention and emergency planning


85. Is smoking prohibited in all operation-related areas?

86. Do the electrical installations meet requirements for the different hazardous areas (zones)?

87. Are adequate provisions made to ensure that heat-sensitive products do not come in contact with hot surfaces?

88. Are mechanically generated sparks avoided by the

• elimination of tramp metal?• checking of rotating parts for clearance,

friction, etc. ?

89. Are the fork-lift trucks adequately protected for the hazardous areas (zones) in which they are used?

90. Is all auxiliary equipment used in the plant suitable for the zone concerned?

91. To avoid the risk of electrostatic discharges, are all facilities and packaging materials properly earthed?

99



92. Is battery charging equipment separated and well-ventilated?

93. Is there a written work permit procedure in place to authorise dangerous non-routine activities, which can produce ignition sources? (e.g. welding or drilling)

94. Are there means to sound an alarm in the plant and to call the fire brigade?

95. Is there an automatic fire detection and alarm system?

96. Is there a sprinkler system?

97. Do the number and type of fire extinguishers, hydrants, and hose lines satisfy the requirements?

98. Is there a fully trained team for fire emergencies on-site?

99. Is the fire-fighting equipment and other safety equipment of the plant (e.g. automatically closing doors, lightening protection) regularly checked and maintained?

100. Has an emergency plan been set up for all emergencies?

Does it include collaboration with the local fire service and the local hospital?

101. Is a fire drill regularly practised in co-operation with the local fire service?

100

Checklist



102. Is there special equipment available to deal with spills and is it kept in a readily accessible location?

103. Are spillages immediately removed, using a written clean-up procedure?

104. Where outside drains exist, can they be rapidly plugged in an emergency?



105. Are efforts commonly made to avoid or minimise the occurrence of contaminated air, waste water or waste?

106. Are efforts made to avoid the uncontrolled dilution of contaminated air and waste water?

107. Are efforts made to recycle products and packaging materials?

108. Is an approved option for the treatment of contaminated air available, such as :

• filtration?• scrubbing?• adsorption/absorption?• others? ........................................

101



109. Is an approved option for the treatment/disposal of contaminated waste water available such as :

• flocculation? • adsorption/absorption?• chemical treatment? `• biological treatment?• others?

110. Are the wastes separated in different hazard categories?

111. Is there a covered designated area for waste on-site?

112. Is there at least one approved option of waste disposal for each of the categories of wastes?

113. Do you follow the provisions of the steel drum disposal decision tree?

114. Are drums and containers, which are not re-used or re-conditioned made unusable before disposal?

115. Is low-density waste compacted and well-packed and labelled before transport to disposal?

116. Are records kept of all the wastes disposed of?

102

Checklist


Definition (Glossary)

Auto-ignition Ignition without input of energy from an external source (e.g.decomposition, oxidation).

Auto-ignition temperature The lowest temperature at which auto-ignition can occur.

Deflagration of solid materials Deflagration in this context is a locally initiated exothermicdecomposition reaction, which is self-propagating even in theabsence of oxygen (contrary to a normal combustion).

Dust The term «dust» or «powder» refers to solids with a diameterless than 0,5 mm. Dust can be formed during the processing ofsolid materials like milling or mixing. Small dust fractions maybe present in coarse materials and can be formed by abrasion(e.g. granular products).

Exothermic decomposition Decomposition of a thermally unstable material with release ofheat. No air is needed to support this process. The heatgenerated by decomposition (if it cannot dissipate) acceleratesdecomposition exponentially, which may result in a run-awayreaction. The mass volume of material can be of criticalimportance to the occurrence of exothermic decompositionsince, in general, the greater the mass the more difficult it will befor the heat generated within the substance to dissipate. Thisfactor must be taken into account when extrapolating dataderived from small-scale tests to larger masses.

ExplosionAbrupt oxidation or decomposition reaction producing anincrease in temperature, pressure, or both simultaneously.

Flash point The flash point is the lowest temperature of a liquid at whichunder given test conditions the vapour above the liquid can beignited.

103


Ignition point (Ignition temperature) Lowest temperature of a hot surface atwhich a dust or vapour/air mixture at given test conditions willignite.

Maximum Explosion Pressure (MEP)Maximum pressure occurring in a closed vessel during anexplosion determined under specified test conditions.

Maximum rate of explosion pressure riseMaximum value of the pressure rise per time unit during anexplosion in a closed vessel under specified test conditions.

Minimum Ignition Energy (MIE)Lowest energy which is just sufficient to effect ignition underspecified test conditions.

Limiting Oxygen Concentration (LOC)The lowest oxygen concentration in a mixture of combustiblesubstances and air, below which an explosion will not occur.

CombustibleSubstance in the form of gas, vapour, liquid, solid, or mixtures ofthese, able to undergo an exothermic reaction with air whenignited.

Lower Explosion Limit (LEL)Concentration of a combustible in mixture with oxidisingatmosphere (generally air), just below the explosion range.

Upper Explosion Limit (UEL) Concentration of a combustible in mixture with oxidisingatmosphere (generally air), just above the explosion range.

Explosion rangeRange of the concentration of a combustible in mixture withoxidising atmosphere (generally air), in which an explosion canoccur.

104

Definitions (Glossary)


Explosion-pressure proofProperty of vessels, apparatus and equipment designed towithstand the expected explosion pressure without becomingpermanently deformed.

Explosion-pressure shock-proofProperty of vessels, apparatus and equipment designed towithstand the expected explosion pressure, but allowingpermanent deformation.

Hybrid mixture Air/dust mixture which contains a flammable gas and/or aflammable vapour.

Tramp metal Undesirable metal objects or particles included in the powderwhich may cause friction sparks during processing.

105


Useful references

CropLife International publications

Guidelines for the safe and effective use of crop protectionproducts.

Guidelines for emergency measures in cases of crop protectionproduct poisoning.

Guidelines for quality control of crop protection products.

Guidelines for the safe transport of crop protection products.

Guidelines for the avoidance, limitation and disposal ofpesticide waste on the farm.

Guidelines for safe warehousing of pesticides.

Guidelines for personal protection when using pesticides in hotclimates.

Guidelines for writers of crop protection product labels andliterature.

Disposal of unwanted pesticide stocks - Guidance on theselection of practical options.

Recommendations for one-way agrochemical packaging designcriteria for liquids and solids.

All the above are available from CropLife International.

106


© 1997 CropLife International

No part of this booklet can be reproduced in any mannerwhatsoever without written permission.

Dépôt Légal : D/1997/2537/1

Design : Créastyl (Stéphane Sabbe - Tel/Fax : +32 81 40 18 28)Illustrations : Norman LaceyPrinted in Belgium by Créastyl

Packing cover.cor 25/10/02 17:34 Page 2

GGUU

IIDDEELL

IINNEESS

FOR

THE

SAFE

FORM

ULA

TIO

NA

ND

PAC

KIN

GO

FC

ROP

PRO

TEC

TIO

NPR

OD

UC

TS

CropLife InternationalAvenue Louise 143B-1050 Brussels - BelgiumTelephone : +32 2 542 04 10Facsimile : +32 2 542 04 19E-mail : [email protected] site : www.croplife.org

Packing cover.cor 25/10/02 17:34 Page 1

guidelines · 2004. 8. 7. · accumulation of heat, thermally unstable products can generate...

Documents