Safety analysis of ammonia exposure at a chemical plant

Abstract

The Environmental Protection Agency (EPA) is issuing this Alert as part of its ongoing effort to protect human health and the environment by preventing chemical accidents. In chemical manufacturing industry, there are many hazards in the workplace particularly chemical hazard. Although there is safe work procedure for activities involving chemical handling, however, incidents of ammonia exposure are still occuring. Therefore, assessment on the workplace conditions and the knowledge and attitude of employees is essential to evaluate the extent of the problem. Accordingly, the objectives of this study are to (1) identify potential exposures, possible effects and root causes of ammonia exposure to workers, (2) to analyse knowledge and attitude of workers on ammonia exposure, and (3) to propose recommendations (guideline) for the improvement of safety handling of ammonia. A Job Safety Analysis was conducted to identify potential exposures, possible effects and root causes of ammonia exposure to workers. Knowledge and attitude questionnaire was conducted for 36 production workers of a company to analyse their knowledge and attitude on ammonia exposure. The results show that the potential ammonia exposures were from this areas; improper carboy cap fastening and lid absence, transfer spillage, residuals splashes, overcharging and continuous pumping, hose leakage, loose and dismantled, rushed scooping, manhole exposure, and charge-in pump not halted. The possible effects of ammonia exposures are carboy leaked, overspill, hose leaked, forced out through loosened hose, ammonia evaporated to fumes, ammonia fumes inhaled into respiratory system, sprinkles and splashes, and direct contact with skin and eyes. The root causes of ammonia exposures are; no initial checking, not wearing PPE, improper pouring method, mixing tank unattended, procedure overlooked, rushing, not following proper procedure, and pump control unattended. The workers’ knowledge of ammonia exposure was high, whereas their attitude was moderate. A guideline was proposed to improve safety handling of ammonia and enhance the knowledge and attitude of workers.