PETRONAS TECHNICAL STANDARDS HEALTH, SAFETY AND ENVIRONMENT GUIDELINE BENZENE PTS 60.1502.01 SEPTEMBER 2011 PETRONAS © 2010 PETROLIAM NASIONAL BERHAD (PETRONAS) All rights reserved, No part of this document may be reproduced, stored in a retrieval system or ‘transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.PTS Circular PET 2011 ETRONAS PTS No: 60.1502.01 PTS Title: BENZENE - This revision of PTS 60.1501.02 - BENZENE (September 2011, Revision 1) has been updated to incorporate PETRONAS Lessons Leamt, Best Practice and new information issued by relevant industry code and standards. All updates in the document are highlighted in italic font. The previous version of this PTS 60.1501.02 BENZENE (September 2004) will be removed from PTS binder / e-repository from herein onwards. ‘The custodian of this PTS is: Manager - HSE MS, Standards & Regulations, GHSED. Please direct any questions regarding this PTS to the above-mentioned. Document Approval — [Name Designation Date [Signature Prepared | Norhazlina Mydin_ | Principal- Industrial Hygiene, GHSED 26.9200] Xt — Technical | Azizin Zainudin | Principal- Industrial Hygiene, . Approved GHSED 26.4211 ‘Approved | Mohd Tarmizi Bin | Head, a.l0.en Munir Group HSE Division Revision History Date | Version Description of Updates Author SEPT | S004 ORIGINAL | NA GHSED SEPT Revision on overall content to reflect current 2014 REVISION 1 _| technology and industry best practice one PTS 60.1502.01 SEPTEMBER 2011PREFACE PETRONAS Technical Standards (PTS) publications reflect the views, at the time of Publication, of PETRONAS OPUs/Divisions. They are based on the experience acquired during the involvement with the design, construction, operation and maintenance of processing units and facilities. Where appropriate they are based on, or reference is made to, national and international standards and codes of practice ‘The objective is to set the recommended standard for good technical practice to be applied by PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical plants, marketing facilities or any other such facility, and thereby to achieve maximum technical and economic benefit from standardization The information set forth in these publications is provided to users for their consideration and decision to implement. This is of particular importance where PTS may not cover every requirement or diversity of condition at each locality. The system of PTS is expected to be sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to their own environment and requirements, When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the quality of work and the attainment of the required design and engineering standards. In particular, for those requirements not specifically covered, it is expected of them to follow those design and engineering practices which will achieve the same level of integrity as Teflected in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his own responsibility, consult the owner, The right to use PTS rests with three categories of users: 4) PETRONAS and its affiliates, 2) Other parties who are authorized to use PTS subject to appropriate ‘contractual arrangements. 3) Contractors/subcontractors and Manufacturers/Suppliers under a contract, with users referred to under 1) and 2) which requires that tenders for projects, materials supplied or - generally - work performed on behalf of the said users ‘comply with the relevant standards, Subject to any particular terms and conditions as may be set forth in specific agreements with users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury or death) suffered by any company or person whomsoever asa result of or in connection with the use, application or implementation of any PTS, combination of PTS or any part thereof. The benefit of this disclaimer shall inure in all respects to PETRONAS and/or ‘any company affliated to PETRONAS that may issue PTS or reauire the use of PTS. Without prejudice to any specific terms in respect of confidentiality under relevant contractual arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by users to any company or person whomsoever and the PTS shall be used exclusively for the purpose they have been provided to the user. They shall be returned after use, including any copies which shall only be made by users with the express prior written consent of PETRONAS. The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe custody and PETRONAS may at any time require information satisfactory to PETRONAS in order to ascertain how users implement this requirement, PTS 60.1502.01 SEPTEMBER 2011PREFACE. TABLE OF CONTENTS 10 2.0 3.0 40 5.0 6.0 7.0 9.0 TABLE OF CONTENTS ne ‘SCOPE... OBEJCTIVE. BACKGROUND. INTRODUCTION HAZARD IDENTIFICATION 5.1 Routes Of Exposure. 5.2 Health Effects of Benzeni 5.21 Acute Health Effects 5.22 Chronic Health Effects. 5.3 Occupational Exposure. 5.3.1 Permissible Exposure Limit (PEL) .. 5.3.2 Action Level. RISK ASSESSMENT. 6.1 Qualitative Assessment 6.41.4 Stage 1: Identify . 6.1.2 Stage 2: Assess. 6.1.3 Stage 3: Control. 6.2 Exposure Monitoring wu 6.2.1. Benzene Sampling and Analysis. CONTROL MEASURES. 7.4 Engineering Control Methods. 7.2 Administrative Control Methods 7.3 Personal Protective Equipment (PPE) 7.3.1. Respiratory Protection .. 7.3.2 Protective Clothing... ASSESSING RECOVERY MEASURES 8.1 Emergency And Firct Aid Procedures 8.1.1 Eye And Face Exposure 8.41.2 Skin Exposure... 8.1.3. Breathing .. 8.1.4 Swallowing, BENZENE HEALTH SURVEILLANCE... 9.1 Pre-Placement Medical Examin 9.2 Biological Monitoring .... 9.2.1 Routine Exposure .. 9.2.2 Non-routine Exposure 8.3 Biological Effect Monitorin PTS 60.1502.01 SEPTEMBER 201110.0 11.0 12.0 9.4 Medical Examination. 9.4.1 Periodic Medical Examinations .. 9.4.2 Exit Medical Examination.. 9.5 Medical Removal Protection 9.54 9.5.2 Criteria For Return To Work... INFORMATION, INSTRUCTION AND TRAINING ... 10.3 Safety Data Sheet (SDS).. 10.4 Compliance Program: RECORD KEEPING. 11.4 Medical And Personal Monitoring Reports 11.2. Transfer Of Records REFERENCES .. PTS 60.1502.01 ‘SEPTEMBER 20114.0 SCOPE This document applies to work areas where exposure to benzene could be expected. This Guide is to be used by OPU/JV for the use, handling , storage and transportation of benzene either as a product or residue 2.0 OBEJCTIVE The specific objectives of this Guide are: 1. To protect workers/employees from the health effects arising from the exposure to benzene handled in workplaces 2. To state the requirement in meeting PETRONAS standards with respect to benzene 3. To outline steps involved to carry out benzene risk assessment, exposure monitoring, control measures and health surveillance 3.0 BACKGROUND This document is intended as a Guide on the safe handling of benzene in the workplace. It provides guideline by which the management of each company can assess its own procedures and practices, and should be read in conjunction with PTS 60.1502 Chemical Management Program and the statutory reguiations. In Malaysia, a regulation on Occupational Safety and Health (Use and Standards of Exposure of Chemicals Hazardous to Health) Regulations 2000 or USECHH 2000 that address on the Use of chemicals which includes benzene in the workplace is one of the main reference of this Guideline. Countries with more stringent statutory regulations shall use this Guideline as reference only. ‘The recommended precautionary measures may serve as a basis for the dratting of procedures of a company specific to its local conditions and circumstances, ‘Additional information concerning the handling of benzene may be obtained trom the publications listed at the end of this Guide. 4.0 INTRODUCTION Benzene is formed from both natural processes and human activities. Natural sources of benzene include volcanoes and forest fires. Benzene is also a natural part of crude cil, gasoline, and cigarette smoke. Some industries use benzene to make other chemicals that are used to make plastics, resins, and nylon and synthetic fibers. Benzene is also used to make some types of lubricants, rubbers, dyes, detergents, drugs, and pesticides, Outdoor air contains low levels of benzene from tobacco smoke, motor vehicle exhaust, and industrial emissions. However, air around hazardous waste sites or gas stations may contain higher levels of benzene than in other areaswhile benzene in indoor air comes from products that contain benzene such as glues, paints, furniture wax, and detergents, Benzene is a common agent in industrial (e.g. E&P operations, petroleum refineries and petrochemical manufacturing) and transportation settings leading to widespread environmental and occupational exposures. Hence, in PETRONAS OPUIJVs workers exposure to benzene could be expected PTS 60.1502.01 SEPTEMBER 20115.0 HAZARD IDENTIFICATION BENZENE (CeHs) CAS 71-43-2; UN NO: 1114 (Synonyms include benzol, coal tar naphtha, pheny| hydride, and cyclohexatriene) Benzene is a highly volatile, flammable liquid. Its vapor is heavier than air and may accumulate in low-lying areas. Benzene is less dense than water and will cat on the surface of water. It is only slightly soluble in water but readily soluble with most organic solvents. At room temperature, benzene is a clear, colorless-to-light yellow liquid that is highly flammable. Because it is volatile, it can spread to a distant source of ignition. Benzene's sweet aromatic odor generally provides adequate warning of hazardous concentrations for acute exposurehowever, inadequate for chronic exposure, Benzene odor is a bad indicator for chronic exposure as at the range of 0.5 to 1 ppm, at which the presence of benzene in the environment would not be realized, it. can cause adverse health effects. Information of Benzene may be obtained from manufacturer's and supplier's ‘SDS/MSDSICSDS, labels on containers or manuals of products; databases or published texts, (e.g. PETRONAS Datakimia);OPU / JV guidance material 5.1 Routes Of Exposure The main route of exposure to benzene, whether liquefied or gaseous form, is through inhalation of its vapour. Odour threshold of benzene is 1.5 ppm to 5 ppm and provides adequate warning of acutely hazardous concentrations. ‘Skin/eyecontact with benzene may result in eye/skin irritation. Repeated or prolonged skin contact with liquid benzene can degrease the skin, causing it {0 crack and could contribute to systemic toxicity Ingestion of benzene could occur due to accidents, poor work practice or personal hygiene. Ingestion could result in acute toxic effects such as nausea, vomiting and abdominal pain and irritation of the respiratory and digestive systems. Persons exposed only to benzene vapor do not pose substantial risks of secondary contamination to others. However, persons whose clothing or skin is contaminated with liquid benzene can cause secondary contamination by direct contact or through off-gassing, 5.2 Health Effects of Benzene Benzene Is classified as a proven human carcinogen by the Commission of the European Communities. The Intemational Agency for Research on Cancer (IARC) has concluded that there is sufficient evidence for carcinogenicity to humans. The overall IARC evaluation is Group 1 - carcinogenic to humans. PTS 60.1502.01 ‘SEPTEMBER 2011‘The American Conference of Governmental Industrial Hygienists (ACGIH) has designated benzene as a confirmed human carcinogen (A1).There are many case reports and epidemiologic studies of exposed workers, that 2 causal relationship between benzene exposure and leukemia has been clearly established. Benzene exposure has also been associated with cancer of the lymph system (lymphoma), lung cancer and bladder cancer. Benzene affects the hematologic (blood) system, For example, it can cause bone marrow not to produce enough red blood cells, which can lead to anemia. Also, it can damage the immune system by changing levels of antibodies in the blood as well as causing the loss of white blood cells. ‘The seriousness of poisoning caused by benzene depends on the amount, route, and length of time of exposure(duration), as well as the age and preexisting medical condition of the exposed person. 5.2.4 Acute Health Effects The effects of acute exposure to high concentrations of benzenei.. neurological, gastrointestinal, dermal and respiratory effects can be evident immediately after exposure. Neurological effects Neurological effects appear to be due primarily to the direct effects of benzene on the central nervous system. The anesthetic action of benzene on the central nervous system is similar to that of other anesthetic gases, first inducing excitation followed by depression, and if exposure continues, death through respiratory failure. Gastrointestinal effects. ‘Swallowing of the liquid may cause aspiration of vomit into the lungs. Signs and symptoms of chemical (aspiration) pneumonitis may include coughing, gasping, choking, burning of the mouth, difficult breathing, and bluish coloured skin (cyanosis). Gastrointestinal tract discomfort may produce nausea and vomiting. In an ‘occupational setting however, ingestion of insignificant quantities is not thought to be cause for concer.Accidental ingestion of benzene may be harmful; animal experiments indicate that ingestion of less than 150 gram may be fatal or may produce serious damage to the health of the individual. Dermal effects Benzene produces moderate skin irritation; evidence exists, or practical experience predicts, that the material produces moderate inflammation of the skin in a substantial number of individuals following direct contact. Skin irritation may also be present after prolonged or repeated exposure; this may result in a form of contact dermatitis (nonallergic). The dermatitis is often characterised by skin redness (erythema) and swelling (oedema) which may progress to blistering (vesiculation), scaling and thickening of the epidermis, 8 PTS 60.1502,01 ‘SEPTEMBER 2011‘At the microscopic level there may be intercellular oedema of the spongy layer of the skin (spongiosis) and intracellular oedema of the epidermis. Entry into the blood-stream through, for example, cuts, abrasions, puncture wounds or lesions, may produce systemic injury with harmful effects. Toxic effects may result from skin absorption.Benzene has an exposure limits with "skin" notation indicating that its vapour and liquid may be absorbed through intact skin. Contact with eyes and mucous membranes may also contribute to overall exposure. Absorption by skin, eyes and mucous membranes may exceed that of vapour by inhalation exposure, Respiratory Effects Inhalation of vapours may cause drowsiness and dizziness. This may be accompanied by narcosis, reduced alertness, loss of reflexes, lack of coordination and vertigo. Acute effects from inhalation of high concentrations of vapour are pulmonary irritation, including coughing, with nausea; central nervous system depression - characterised by headache and dizziness, increased reaction time, fatigue and loss of co-ordination, Central nervous system (CNS) depression may include nonspecific discomfort, symptoms of giddiness, headache, dizziness, nausea, anaesthetic effects, slowed reaction time, slurred speech and may progress. to unconsciousness. Serious poisonings may result in respiratory depression and may be fatal The symptoms of exposure to high vapour concentrations of benzene include confusion, dizziness, tightening of the leg muscles and pressure over the forehead followed by a period of excitement. If exposure continues, the casualty quickly becomes stupefied and lapses info a coma with narcosis. In non-fatal cases, recovery is usual. Effects of inhalation may include nausea, vomiting, headache, dizziness, drowsiness, weakness, sometimes preceded by brief periods of ataxia, staggering, weak and rapid pulse, chest pain and tightness with breathlessness, pallor, cyanosis of the lips and fingertips and tinnitus, Severe exposures may produce blurred vision, shallow rapid breathing, delirium, cardiac arthythmias, unconsciousness, deep anaesthesia, paralysis and coma characterised by motor restlessness, tremors and hyperreflexia - ‘occasionally preceded by convulsions. 5.2.2 Chronic Health Effects Benzene can cause serious damage if one is exposed to it for long periods. It can be assumed that it contains a substance which can produce severe defects. This has been demonstrated via both short- and long-term experimentation Substance accumulation, in the human body, may occur and may cause some concer following repeated or long-term occupational exposure. PTS 60.1502.01 SEPTEMBER 201153 Chronic exposure to benzene may cause headache, fatigue, loss of appetite and lassitude with incipient blood effects including anaemia and blood ‘changes. Benzene is a myelotoxicant known to suppress bone- marrow cell proliferation and to induce haematologic disorders in humans and animals. Occupational exposures have shown a relationship between exposure to benzene and production of myelogenous leukaemia. In chronic exposure, workers exhibit signs of central nervous system lesions and impairment of hearing. 5.3.1 Permissible Exposure Limit (PEL) Exposure to benzene should be controlled to a level ‘as low as reasonably practicable’ (ALARP) and shall, in any case, be less than PEL. ‘The PEL to be used in all PETRONAS OPU/JVs within or outside Malaysia is 0.5 ppm (1.6 mgim*) TWA over eight hours. However, if the local statute stipulates an exposure limit that is more stringent than this, then the local limit, shall be used For Short term exposure limit (STEL), OPUNJV shall assure that no employee is exposed to an airborne concentration of benzene in excess of 2.5 ppm as averaged over any 15 minute period Below are other limits set for benzene by the relevant bodies for references US Occupational Safety and Health Administration | PEL1 ppm STEL 5 ppm. (OSHA) US National Institute of Occupational Safety PEL 0.1 ppm STEL T ppm ‘Health (NIOSH) IDLH 800 ppm ‘American Conference of Govermental Indutvial | PELOS ppm STEL 2.5 ppm Hygiene (ACGIH) ‘American Industrial Fygiene Association (AIHA) | ERPG-2 150 ppm. Department” of Occupational Safely & Health | PELOS ppm, STEL 25 ppm (D0SH) Malaysia PEL Permissible Exposure Limit (based on 8 hours time weighted average). Is also referred to the generic term Occupational Exposure Limit (OEL) sTeL ‘Short Term Exposure Limit IDLH Immediate Danger to Lite or Heath ERPG-2 (maximum airborne concentration below which it is believed that nearly al persons could be exposed for up to 1 hour without experiencing or developing ireversibe of other serious health effects or symptoms that could impair their ablities to take protective action) 5.3.2 Action Level ‘Action level refers to an airbome concentration of benzene of 0.5 ppm calculated as an 8-hour time-weighted average 10 PTS 60.1502.01 SEPTEMBER 20116.0 RISK ASSESSMENT In an area where there is a likelihood that 2 worker may be exposed to benzene during work, 2 written assessment on the risks created by the exposure to the health of the worker shall be conducted. A Health Risk Assessment (HRA) or Chemical Health Risk Assessment (CHRA) or specific Benzene Health Risk Assessment, shall be carried out by a competent person and based on the PETRONAS HRA methodology or recognized methodology. The PETRONAS HRA methodology of assessment is available in PTS 60.1400.01 Health Risk Assessment. ‘Any recommendations from the assessment should be acted upon by the management, The assessment should be reviewed periodically, at least every 5 years, or more often if there are ‘any changes to the work processimethod or any circumstantial changes in the work being assessed or it the local statute stipulates a more frequent internal then the local frequency shall be used The following subsection describes the general steps in carrying out qualitative risk assessment. 64 6.1.4 Stage 1: Identify It is important to identify the presence of benzene in an OPUIJV facility as it is one of the major health hazards. The presence of benzene in a location may be obtained from the process design specification, product specification, lab analysis report or plant process mapping, As a first step, it is necessary to set the boundaries or scope of the benzene health risk assessment. The activities, tasks that may expose the workers to benzene should be defined 6.1.2 Stage 2: Assess Important considerations in the assessment of benzene exposure in the workplace are: Frequency of exposure (Daily’Weekly/Monthly/Yearly) Duration of exposure (% of work/ minutes/hours) + Intensity or magnitude of exposure + Methods of handling The intensity or magnitude of exposure may be evaluated quantitatively or qualitatively. The resuts from the past personal or area exposure monitoring gathered may be used to estimate the exposure to benzene, Direct reading instruments for benzene may also be used for the estimation. On the other hand, qualitative estimates of exposure depend on the degree of benzene release or presence. "1 PTS 60.1502.01 ‘SEPTEMBER 201162 6.1.3. Stage 3: Control Evaluation of the existing control measures includes the following: ‘© Identify current benzene control measures installed at site in the removal of reduction of benzene * Provision of PPE specific to benzene, training on safe handling of benzene ‘© The adequacy of the existing controls will be evaluated based on its, suitability, use, effectiveness and maintenance When any exposures are over the PEL, the OPUIJV shall establish and implement a written program to reduce employee exposure to or below the PEL primarily by means of engineering and administrative controls. ‘When it is not feasible to control the risks by other levels of control hierarchy, PPE (either on its own or in combination with other controls), may be used as ‘a control option to minimise personal exposure, Section 7.0 describes the relevant control measures that can be considered for controlling benzene Exposure Monitoring Exposure monitoring for Benzene shall be conducted based on the followingarrangement: «As per the recommendation of Health Risk Assessment (HRA) or Chemical Health Risk Assessment (CHRA) or specific Benzene Health Risk Assessment (Benzene HRA) ‘+ As part of investigation * As directed by the local authority and or PETRONAS Management The above exposure monitoring arrangement includes the situationwhen there has been @ change in the production, process, control equipment, personnel or work practices which may result in new or additional exposures, to benzene, or when the employer has any reason to suspect a change which may result in new or additional exposures. Exposure Monitoring must be carried out by competent personnel. The exposure monitoring shall be carried out in accordance with an approved monitoring and analytical protocols such as US-NIOSH Manual of Analytical Methods and OSHA Method. A monitoring strategy is required to ensure the initial objectives are met. Exposure monitoring considerations for Benzene should include: ‘= Determinations of employee exposure shall be made from breathing zone air samples that are representative of each employee's average ‘exposure to airborne benzene. 12 PTS 60.1502,01 SEPTEMBER 2011‘+ Representative 8-hour PEL employee exposures shall be determined on the basis of one sample or samples representing the full shift exposure for each job classification in each work area, ‘+ Determinations of compliance with STEL shall be made from 15 minute employee breathing zone samples measured at operations where there is reason to believe exposures are high, such as where tanks are opened, filled, unloaded or gauged; where containers or process equipment are opened and where benzene is used for cleaning or as @ solvent in an uncontrolled situation. Monitoring for the STEL shall be repeated as necessary to evaluate exposures of employees subject to short term exposures. 6.2.1 Benzene Sampling and Analysis ‘Sampling and analysis must be performed with recognized procedures. The US NIOSH Manual of Analytical Methods (NMAM) or other equivalent document should be referred to determine the protocol for sampling and analysis of Benzene ‘The sampling and analysis may be performed by collection of the benzene vapor or charcoal absorption tubes, with subsequent chemical analysis by gas chromatography. Sampling and analysis may also be performed by portable direct reading instruments, real-time continuous monitoring systems, passive dosimeters or other suitable methods. The OPUNJV has the obligation of selecting a monitoring method which meets. the accuracy and precision requirements of the standard under his unique field conditions. The standard requires that the method of monitoring must have an accuracy, to a 95 percent confidence level, of not less than plus or minus 25 percent for concentrations of benzene greater than or equal to 0.6 ppm. Benzene Sampling Sampling for Benzene can be conducted by either active or passive sampling, ‘Active Sampling This method uses mechanical force to draw gaseous benzene samples into a sampling media which traps benzene within its matrices Passive Sampling This method relies on passive diffusion of gases onto sampling media. Passive organic vapor badges (e.g. 3M badges) for benzene shall be used, 13 PTS 60.1502,01 SEPTEMBER 2011Area to be Sampled Area or environmental monitoring is carried out to measure benzene airborne concentration in working environment. This method of monitoring will indicate what the concentration and distribution of benzene is at a particular area. This information is useful for improvement of working environment Personnel to be Sampled Personal exposure monitoring is to monitor benzene exposure to workers as it monitors directly the exposure level irrespective of their movement in the workplace or change of working environment. Benzene Analytical Methods ‘Sampling media are recommended fo be sent to an accredited analytical lab to determine the concentration of benzene exposed. “ PTS 60.1502.01 SEPTEMBER 20117.0 CONTROL MEASURES The OPU/JV shall institute engineering controls and work practices to reduce and maintain employee exposure to benzene at or below the permissible exposure limits, except to the extent that the employer can establish that these controls are not feasible. TA 72 73 Engineering Control Methods Engineering control methods to reduce benzene includes mechanical ventilation (dilution and local exhaust), process or personnel enclosure, control of process conditions, and process modification. Vapor contro! system is example of engineering control that is used for containing the total vapors displaced during the loading of gasoline, motor fuel or other fuel tank trucks and the displacing of these vapors through a vapor processing system or balancing the vapor with the storage tank Administrative Control Methods When engineering controls cannot eliminate or reduce the exposure, work practices and procedures shall be implemented to reduce the exposure of benzene in the workpiace to an acceptable level. This includes ‘+ minimising the period of exposure to benzene; + minimising the number of employees exposed and exclude non-essential access; * establish own written "Benzene Procedures” specifying safe methods of handling * provide facilities for washing and drying, changing and separate storage of personal and work clothing, including arrangements for laundering contaminated clothing; and * personal hygiene practices ie. smoking, eating or drinking should not be Permitted while working with benzene, Personal Protective Equipment (PPE) Personal protective clothing and equipment (PPE) are not substitutes for effective engineering controls, safe working conditions or sound work practices, but can play an essential part in the protection of the worker. Its use does not eliminate the hazard but is an aid in controling individual exposure so as to prevent adverse health effects. ‘Where exposure monitoring indicates that personnel may be exposed to potentially hazardous concentrations of benzene vapour, personal protective equipment (PPE) should be used. This may include respiratory protection and protective clothing, 15 PTS 60.1602.01 ‘SEPTEMBER 20117.3.1 Respiratory Protection Wherever the feasible engineering controls and work practices which can be instituted are not sufficient to reduce employee exposure to or below the PELs, the OPUNJV shall use them to reduce employee exposure to the lowest levels achievable by these controls and shall supplement them by the use of respiratory protection. Such protection may range from simple air purifying cartridge respirators with half or full face masks through to positive pressure self-contained breathing apparatus. ‘Should uncertainty exist as to the actual benzene vapour concentrations, it should be assumed that concentrations exceed the PEL until such time as monitoring indicates whether or not a hazard actually exists. Based on the NIOSH pocket guide for Benzene, the following respirators are required at different concentration or condition of use Airborne Concentration ‘or Condition of Use 0.5 ppm to 10 ppm 10 ppm to 50 ppm ‘50 ppm to 100 ppm 100 pom to 1,000 ppm > 1,000 ppm or unknown concentration Escape Firefighting Required Respirator Half-mask air-purifying respirator with organic vapor cartridge. (1) Full facepiece respirator with organic vapor cartridges; or (2) Full-faceplece gas mask with chin-style canisters”. Fulkfacepiece powered air-purifying respirator with organic vapor canister’ ‘Supplied-air respirator with full facepiece in positive-pressure mode. (1) Seif-contained breathing apparatus with ful facepiece in positive-pressure mode; or (2) Full facepiece positive-pressure supplied-air respirator with auxiliary self-contained air supply. (1) Any organic vapor gas mask; or (2) Any self-contained breathing apparatus with full facepiece. FulLfacepiece self-contained breathing apparatus in positive- Pressure mode. *Canisters must have a misimum service life of four (4) hours when tested at 150 ppm benzene, at a flow rate 0f64 liters per minute (LPM), 25°C, and 85% relative humidty for non-powered air purying respirators. The ‘low rate shal be 115 LPM and 170 LPM, respectively, or tight-iting and loose-iting powered air-purfying respirators. Table1: Benzene Respirator Requirement 16 PTS 60.160201 ‘SEPTEMBER 20117.3.2 Protective Clothing Although the primary risk ftom benzene is through inhalation of aitborne vapour, it may also be absorbed through the skin. Personnel who may come into contact with activities containing benzene should wear protective clothing such as impervious overalls, aprons, boots, gloves and goggles as appropriate. Details on protecting clothing can be referred PTS on PPE, 60.2114, PPE andPTS on Chemical Management, 60.1502 and SDS on Benzene. 7 PTS 60.1502.01 SEPTEMBER 20118.0 ASSESSING RECOVERY MEASURES Recovery (preparedness) measures are required to mitigate the potential effects should the exposure control measures fail, and to prevent the potential escalation of health risks. This might also be true if the risk in under-estimated in the qualitative assessment or whenever there is an emergency due to accidental benzene exposure such as during spillage or fire in benzene containing equipment. Recovery measures includes; «medical emergency response arrangements + eyewash and shower stations, * escape equipment such as rebreathers, personal alarms, and * post traumatic stress counselling Whenever spills, leaks, ruptures or other breakdowns occur that may lead to employee exposure, monitoring of benzene prior to spill clean up is deemed necessary to determine the necessary type of PPE to be used. The OPU shall monitor (using area or personal sampling) after the cleanup of the spill or repair of the leak, rupture or other breakdown to ensure that exposures have returned to the level that existed prior to the incident 8.1 Emergency And Firct Aid Procedures 8.1.1 Eye And Face Exposure If benzene is splashed in your eyes, wash it out immediately with large ‘amounts of water. If irritation persists or vision appears to be affected see a doctor as soon as possible. 8.4.2 Skin Exposure If benzene is spilled on your clothing or skin, remove the contaminated clothing and wash the exposed skin with large amounts of water and soap immediately. Wash contaminated clothing before you wear it again. 8.1.3 Breathing If you or any other person breathes in large amounts of benzene, get the exposed person to fresh air at once. Apply artificial respiration if breathing has stopped. Call for medical assistance or a doctor 2s soon as possible. Never enter any vessel or confined space where the benzene concentration might be high without proper safety equipment and at least one other person present who will stay outside. A life line should be used. 8.1.4 Swallowing If benzene has been swallowed and the patient is conscious, do not induce vomiting. Call for medical assistance or a doctor immediately 18 PTS 60.1802.01 ‘SEPTEMBER 20119.0 BENZENE HEALTH SURVEILLANCE Benzene Health Surveillance Program shall be established for employees, including contractors’ employees, who have exposure to benzene as per the following entrance criteria 4. Employees exposed to Benzene at or above 0.5 ppm (B-hour time weighted average (TWA.8)) for 30 or more days per year, 2. Employees who are exposed to Benzene at or above 1.0 ppm (TWA-8) during 10 or more days per year, or 3, Employees who are exposed to Benzene at or above 5.0 ppm over 1 minutes 10 or more days per year. Health surveillance program for Benzene shall refer toPTS 60.1501.03 as stated in item 9.1, 10.9.5 below 9.1 Pre-Placement Medical Examination Pre-placement medical should be carried out within 3 months prior to starting ‘work in workplaces or premises that potentially expose the employee to Benzene, Emphasis should be given to: © previous history of exposure to bone marrow toxins including Benzene, ‘+ previous exposure to liver toxins ‘+ status of the blood and blood forming organs. ‘+ status of the liver ‘+ pregnancy test for ladies Laboratory testing should include full blood count including a leukocyte differential count, thrombocyte, haemoglobin, hematocrit, erythrocyte and erythrocyte indices (MCV, MCH, MCHC):and blood morphology. Appropriate additional tests if clinically indicated to determine the cause of alterations in the components of the blood or other signs which may be related to benzene exposure. Individuals with suspected or confirmed problems involving any of the blood forming organs and the liver are not suitable for work with potential exposure to Benzene. Similarly, pregnant employees are unfit for workplaces with Benzene until childbirth or termination of the pregnancy 9.2 Biological Monitoring 9.2.1 Routine Exposure During routine operations, where reliable laboratory facilities are available, employees placed under Benzene Surveillance Program should undergo 6- monthly end-of-shift urine testing for S-Phenyl Mercapturic Acid (S-PMA) or trans, trans-Muconic Acid (tt-MA) 19 PTS 60.1602.01 SEPTEMBER 20119.3 ‘The Biological Exposure Index (BE!) for both is: Bio-markers ‘Analysis Method BET ‘S-PMA GoM 25 ug/ gm of creatinine TEMA HPLC GCMS 500 ug! gm of creatinine | 9.2.2 Non-routine Exposure For non-routine operations (turnaround, spill clean-up, etc.), employees working in work areas with high Benzene level such as tank cleaning, eto. shall undergo post-shift urine testing (within 24 hours) after completion of the work. For work that last for more than one (1) week, the testing should be repeated on weekly basis. Note: 4. Cigarette smoking may increase the body burden of Benzene and should be considered when analyzing the urine result. 2. Urinary S-PMA is preferred to tt-MA especially in very low level of exposure to Benzene (<1 ppm) 3. End-of-shift means collection of sample done as soon as the shift ends. 4. Testing requirements done irrespective of PPE used. Biological Effect Monitoring Initial screening should be done within six (6) months of starting work that exposes the worker to Benzene. Thereafter, the screening should be carried ut during the annual medical examinations or more frequent if clinically indicated or the biological monitoring showed elevated result The screening should include the following laboratory tests: Full Blood Count as detailed under para 3.1 above. + Peripheral Blood Film analysis of blood celis morphology and reticulocyte counts, Abnormalities found require consuitation with a clinical specialist such as a hematologist, to determine the pathology behind the changes. Investigation of the workplace should be carried out to rule out Benzene as the cause for the changes. Biological effect monitoring for employees expose to Benzene during non- routine work should be done within one (1) months post exposure, if the biological monitoring results exceed the BEI. 20 PTS 60.1502,01 SEPTEMBER 20119.4 95 Medical Examination 9.4.4 Peri ic Medical Examinations Participating employees shall undergo annual medical examinations to screen them for signs and symptoms of conditions related to Benzene exposure. The frequency of examination may be increased to 6-monthly or 3- monthly depending on the exposure levels and biological monitoring resuits. 9.4.2 Exit Medical Examination All employees placed under the program shall be required to undergo exit medical prior to exiting the workplace due to transfer, retirement or termination of employment. Medical Removal Protection Every case of suspected or confirmed benzene exposure shall be investigated to determine workplace exposure. Affected employees should be placed under the MRP program 9.5.1 Criteria For MRP ‘Any employee working in workplaces with Benzene and have the following conditions shall be placed under the MRP Program permanently or until such time that retum to the workplace is permissible. (Note - all abnormal blood results shall be repeated within 2 weeks.) + The haemoglobin level or the hematocrit falls below the normal limit outside the 95% confidence interval (C.l)] as determined by the laboratory for the particular geographic area andior these indices show a persistent downward trend from the individual's pre- exposure norms; provided these findings cannot be explained by other medical reasons. + The thrombocyte (platelet) count varies more than 20 percent below the employee's most recent values or falls outside the normal limit (95% C.l,) as determined by the laboratory * The leukocyte count is below 4,000 per mm” or there is an abnormal differential count. ‘+ Signs and symptoms of leukemia or other cancers related to blood forming organs + Pregnant andlor breastfeeding, 9.5.2 Criteria For Return To Work Except for pregnancy, all employees placed under MRP shall undergo medical examination (3 - 6 monthly) to determine if they can return to the workplace. Return to work is permissible on the following ground: 1. Blood cell counts andor morphology has returned to within normal values 2. Pregnancy and/or breastfeeding have ended 2 PTS 60.1502.01 SEPTEMBER 2011Additionally, those eligible for return to work should be given additional protection, where appropriate to ensure they are protected from the Benzene hazard. This protection may include educating them on the risks of Benzene and the correct choice and maintenance of PPE. Employees suspected of developing early signs of blood of other form of cancers or found to have repeat problem with Benzene on their return to work, shall be placed under permanent MRP. Medical surveillance shail include but not limited to the following: ‘+ Full medical history including occupational, medical, social and family history + Information on potential sources of benzene exposure + Signs and symptoms of benzene exposure + Biological monitoring on Benzene 22 PTS 60.1502.01 SEPTEMBER 2011‘The process from Risk Assessment to Return to Work is shown in the diagram below Berzene identified at the workplace ¥ Chemica! Health Risk Assessment NO YES Repeat CHRAIn 5 years {ime or any change in process Conduct Personal Exposure Monitoring Biological ‘monitoring not required NO YES Biological Monitoring / Biological Effect Monitoring Routine / ¥ hanzana exnnes ia no. yes Urine Back to normal » RW Suspected Confirmed —-—— No further action required Undergo medical examination Blood cell counts and/or morphology hos retumed to within normal valves 23 PTS 60.1502.01 ‘SEPTEMBER 201110.0 INFORMATION, INSTRUCTION AND TRAINING 10.4 10.2 10.3 104 Training Workers who are exposed or likely to be exposed to benzene during work shall be given periodical training to give them awareness and knowledge on benzene and their exposure to the chemical ‘The pertinent contents of the training should include information on the risk to their health due to the exposure, the precautionary and preventive measures that need to be taken to protect themselves. It should also include any personal or area monitoring results that affect them and the results of medical surveillance program implemented in the workplace which have been analyzed in a collective manner. Training programmes should be documented and records kept in good and safe condition for inspection, Labeling Materials that contain benzene shall be labeled appropriately in language(s) that workers can understand. The label at a minimum should contain an identification of the chemical, a warning on its dangers and the health and safely risks associated with benzene. Warning signs should be placed at common benzene exposure areas e.g sum pitts, sludge farms, sampling point et cetera. Safety Data Sheet (SDS) A Safety Data Sheet (SDS) should also be available for materials that contain benzene. Under USECHH 2000, the SDS language should be in both national language and English. The label and SDS should be kept in good order and condition, replaced if they have been altered and kept in areas where workers have easy access to them. Compliance Program OPU/JV to establish a compliance program that can be referred from this guideline For any benzene exposures over the PEL, the OPU/JV shall establish and implement a written program to reduce employee exposure to or below the PEL primarily by means of engineering and work practice controls. The written program shall include a schedule for development and implementation of the engineering and work practice controls. These plans shall be reviewed and revised as appropriate based on the most recent exposure monitoring data, to reflect the current status of the program 24 PTS 60.1502.01 SEPTEMBER 201114.0 RECORD KEEPING 11.1 Medical And Personal Monitoring Reports Medical and personal monitoring reports shall be kept by the Company for a period of not less than 30 years after the end of workers’ employment. Records of personnel, environmental and biological monitoring should follow similar arrangementAll reports shall be made available to the relevant authority upon request. 14.2 Transfer Of Records In situations where @ worker has to be transferred to another OPU, his/her medical report shall be relocated accordingly. 25 PTS 60.1502.01 SEPTEMBER 201112.0 REFERENCES 1 2, 10. "1 12. 13, PETRONAS PTS 60.1502 Chemical Management Program, 2009 PETRONAS PTS 60.2204 Personal Protective Equipment (PPE Guideline), 2009 Benzene and leukaemia. An epidemiologic risk assessment. Rinsky RA, Smith ‘AB, Hornung R, et al. New England Journal of Medicine 1987, 316(17): 1044- 1050. CEFIC review and critique of the ACGIH proposal to lower the threshold limit value (TLV) for benzene from 10 ppm - 0.1 ppm. CEFIC Health and Safety Regulations Working Group, March 1991 Exposure to benzene and mortality from leukaemia: results from coke oven and other coal products workers. Hurley JF, Cherrie JW, Maclaren W. 25 February 1991, Letter submitted to British Journal of Industrial Medicine. Occupational Safety and Health (Use and Standards of Exposure of Chemicals Hazardous to Health) Regulations 2000 ~ Malaysia Department of Occupational Safety and Health Malaysia. Guidelines on Medical Surveillance. JKKP: GP (1)/4/2001 (2001) United States Department of Labor. OSHA Standards ~ Benzene — 1910.1028. United Stated National Institute Occupational Safety and Health (NIOSH) Pocket Guide for Benzene Center for Disease Control and Prevention (CDC) website : Facts About Benzene American Conference of Governmental Industrial Hygiene (ACGIH) TLV Booklet, 2009 The US NIOSH Manual of Analytical Methods (NMAM) PETRONAS Online Datakimia (Chemwatch): Chemical safety data sheet on Benzene 268 PTS 60.1502.01 SEPTEMBER 2011