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OCCUPATIONAL SAFETY AND HEALTH
Instructions for labor protection when applying metal coatings, working with acids and alkalis
Occupational Safety and Health / Standard instructions for labor protection Safe Operation 1. General safety requirements 1.1. On the basis of this instruction, labor protection instructions are developed for workers employed in the processes of applying metal plating, when working with acids and alkalis (hereinafter referred to as workers engaged in work with acids and alkalis). 1.2. To perform work with acids and alkalis, workers are allowed at least 18 years of age who have mastered safe methods and techniques for performing work, methods and techniques for the correct handling of mechanisms, devices, tools, as well as with loads. 1.3. To work on hoisting machines controlled from the floor, to hang the load on the hook of such machines, workers are allowed at least 18 years old, trained in a special program, certified by the examination committee of the organization and having a certificate for the right to use hoisting machines and hooking loads. 1.4. When performing work, it is necessary to comply with the accepted technology. It is not allowed to use methods leading to violation of labor safety requirements. 1.5. In case of any questions related to its safe performance in the process of work, you must contact your immediate or higher manager. 1.6. Employees working with acids and alkalis are required to comply with the internal labor regulations of the organization. 1.7. When working with acids and alkalis, a worker may be exposed to dangerous and harmful production factors:
Therefore, failure to follow these instructions may result in poisoning and chemical burns. 1.8. Workers working with acids and alkalis must be provided with personal protective equipment. 1.9. The procedure and conditions for the storage and release of each chemical must be established by the relevant instructions approved by the employer. 1.10. Storage conditions for acids and alkalis must be selected depending on their physical and chemical properties and the classification of hazardous substances. 1.11. It is necessary to store acids in the workshop in a special room with acid-resistant floors and walls in closed acid-resistant tanks or in the container of the supplier plant. Do not store acids in basements. In acid storage facilities, it is necessary to constantly monitor the good condition of tanks and pipelines, timely repair and replacement of fittings, and the quality of flange sealing. The supply of acids in the workshop consumable pantries should not exceed the two-day requirement of the workshop. 1.12. At the entrance to the room where acids are stored, a ramp or threshold should be provided to prevent the liquid from spreading in the event of an accident. 1.13. Acids should be stored in the following containers:
Nitric and sulfuric acid in quantities up to 40 liters can be stored in glass bottles. 1.14. The inner surface of containers intended for the storage and transportation of aggressive liquids capable of entering into chemical compounds with the materials from which the container is made must be rubber-coated or lined with materials resistant to aggressive liquids. 1.15. Do not store acids in a room where cyanide compounds are stored or used. 1.16. In storage warehouses and in places where acids are used, there should be:
1.17. Tanks for transporting acids must be painted with acid-resistant paint and have the inscription "Dangerous acid" and the name of the acids, made in resistant paint. 1.18. Acid bottles placed in wicker baskets with strong handles or wooden crates should be placed in storage areas in groups (of the same name) in 2-4 rows and not more than 100 pcs. in each group. The width of the passages between the rows of bottles must be at least 1 m. The space between the bottle and the basket must be filled with gasket materials impregnated with calcium chloride solution to prevent ignition. Acid bottles must be protected from exposure to sunlight. 1.19. Do not allow gasoline, kerosene, oil and alcohol to enter the acid containers. 1.20. To avoid fire, explosion or release of toxic gases, it is not allowed to store acids and alkalis in the room where magnesium and titanium products are processed. 1.21. Solid caustic soda must be stored in iron drums; liquid caustic soda - in iron cans, barrels and tanks. Containers with caustic soda must be labeled "Dangerous - caustic soda". 1.25. When transfusing acids and alkalis, special devices made of acid-resistant materials (siphons and others) should be used. When using siphons for pouring acids, alkalis and working solutions, the siphons are filled by sucking in the liquid by creating a vacuum or using a compressed gas. Sucking air through the mouth is not allowed. The paragraphs are numbered according to the source. 1.26. When emptying the bottles, it is not allowed to leave acid in them. 1.27. Drainage from drums and tanks should be done by creating a vacuum, or with special acid-resistant pumps. All piping must be made of vinyl plastic or an equivalent material. The tank must be above the drain level. 1.28. With a large consumption of acids, the dangerous and laborious work of draining and issuing acids must be mechanized by constructing pipelines made of acid-resistant materials and installing special pumps for pumping acids in separate rooms. Pumps for pumping acids must have a remote start. Pump room doors must be closed. At a consumption of less than 400 kg of acid per shift, it is allowed to supply them in a tightly closed unbreakable container. 1.29. Pumps, pumps, tanks, pipelines, fittings and other equipment for acid transfusion should be periodically, at least once a quarter, and rubber hoses should be pressure-tested monthly with a pressure exceeding 1 times the working pressure, followed by stamping of the test. 1.30. Each worker in unloading and transport operations is obliged to use overalls, safety shoes and personal protective equipment. Drainage work must be carried out in a gas mask, while the worker must be on the windward side. 1.31. When draining acids from a railway tank into a stationary tank, the discharge hose from the centrifugal pump must be lowered into the upper neck of the tank, and not connected to the drain pipe to avoid water hammer when the pump is turned on. It is not allowed to work with concentrated acids outdoors in rain, blizzard and strong wind. 1.32. Caustic soda drums must be transported on special carts. 1.33. Liquid caustic should be poured with a pump carefully, without splashing, and jelly-like caustic should be poured with a ladle on a long wooden or metal handle. 1.34. Bottles, reservoirs and other containers should be filled with acid or other chemical solutions to no more than 0,9 of their capacity. 1.35. At work sites where nitric acid is used, there should be no combustible substances, materials and waste (chips, sawdust and other materials). 1.36. In the event of an accident, a worker working with acids and alkalis must stop work, notify his immediate or superior supervisor and seek medical attention. 1.37. An employee working with acids and alkalis must observe the rules of personal hygiene: before eating and after finishing work, wash their hands with warm water and soap. Food must be taken in rooms specially equipped for this purpose. 1.38. Workers working with acids and alkalis should be able to provide first aid to the victim. 1.39. Workers working with acids and alkalis who do not comply with the requirements of this instruction are held liable in accordance with applicable law. 2. Safety requirements before starting work 2.1. Inspect the workplace, put it in order, clear the aisles and do not clutter them up. 2.2. Inspect, tidy up and put on personal protective equipment. 2.3. Check the presence and correctness on the transport trolley:
2.4. Installation of containers with acid or alkali on transport carts should be carried out in accordance with the requirements of technological documentation. 2.5. When working with lifting mechanisms, check their serviceability and comply with the requirements of the relevant labor protection instructions. 3. Safety requirements during work 3.1. Transportation of acids and alkalis is carried out by a special team under the guidance of their immediate supervisor. 3.2. Transportation of acids and alkalis should be carried out in a safe container on special carts, stretchers or frame wooden boxes with handles. 3.3. Do not allow workers who are not associated with this work to transport acids and alkalis. 3.4. Transportation of bottles with acids and alkalis on special carts should be carried out by two workers at a speed of no more than 5 km/h. 3.5. Check on each bottle the presence of a label indicating the name of the acid and alkali, grade, weight and GOST. 3.6. Carrying and lifting bottles with acid and alkali should be carried out only after a thorough inspection of the container. 3.7. Check the suitability of the container for work (serviceability of the handles, no damage, etc.). 3.8. When carrying and lifting bottles with acid and alkali, take the container, not the bottle. Carrying and lifting bottles should be done carefully, as in case of dousing with acid, severe body burns are possible. 3.9. Carrying bottles with acid and alkali by one employee is prohibited. 3.10. Do not put bottles or containers with acid and alkali on the transport trolley together with containers with flammable liquids (gasoline, solvents, etc.). 3.11. Transportation of acids and alkalis is carried out on a trolley equipped with detachable sides with appropriate fasteners. The platform of the trolley must be lined with rubber. 3.12. It is forbidden to transport acids and alkalis directly on the platform of the electric car. 3.13. When transfusing acids and alkalis, use special devices made of acid-resistant materials (siphons and others). When using siphons for pouring acids, alkalis and working solutions, fill the siphons by sucking in the liquid by creating a vacuum, or using compressed gas. Sucking air through the mouth is not allowed. 3.14. When emptying the bottles, do not leave acid in them. 3.15. Drainage from drums and tanks should be done by creating a vacuum, or with special acid-resistant pumps. All piping must be made of vinyl plastic or an equivalent material. The tank must be above the drain level. 3.16. Drainage works should be carried out in a gas mask, while the worker should be on the windward side. 3.17. When draining acids from a railway tank into a stationary tank, lower the discharge hose from the centrifugal pump into the upper neck of the tank, and not connect it to the drain pipe to avoid hydraulic shock when the pump is turned on. It is not allowed to work with concentrated acids outdoors in rain, blizzard and strong wind. 3.18. Drums with caustic soda should be transported on special trolleys. 3.19. Pour liquid caustic with a pump carefully, without splashing, and jelly-like caustic with a ladle on a long wooden or metal handle. 3.20. Fill bottles, tanks and other containers with acid or alkali to no more than 0,9 of their capacity. 3.21. The preparation of electrolytes is carried out in separate, specially equipped rooms under the guidance of a foreman with a permit for high-risk work. 3.22. When preparing a solution from a mixture of acids, introduce acids in ascending order of their density:
Acids are poured into water in a thin stream with thorough mixing. 3.23. Dissolve caustic alkalis in small portions with continuous stirring to avoid ejection of the solution. Alkali is added to the solution using devices that are slowly immersed in water. Adding water to a bath with an aqueous solution of sodium hydroxide is allowed only in a cold solution in order to avoid splashing the solution out of the bath. 3.24. Filling baths with acids and liquid alkalis should be done using siphons with tight taps. The processes of filling large-volume baths with aggressive liquids, as well as pumping solutions from baths, are carried out with special acid-resistant pumps. 3.25. Transfusion of acid or alkali into baths by hand is allowed in exceptional cases only with the help of special devices that ensure the safe installation of the bottle, prevent splashing of the liquid and eliminate the release of vapors. 3.26. Before adding alkali to the oxidation bath, the electrolyte solution should be cooled to a temperature not exceeding 100°C; melt - until hardening. 3.27. To prevent the release of the solution from the oxidation baths during the adjustment of the solutions and the filling of the baths, use special devices (perforated buckets for dissolving alkali, pipes for supplying hot water reaching the bottom of the baths). 3.28. When preparing a hydroboric acid electrolyte, in order to avoid splashing out of the solution, add boric acid to the bath, and then lead carbonate mixed with water (in the form of a slurry) in small portions; the capacity of the bath should be 3 to 4 times the calculated volume of hydroboric acid, the bath should be water-cooled. 3.29. To reduce worker exposure to harmful fumes:
3.30. Discharge of electrolytes, solutions and water from the baths is carried out in a closed way. At the same time, the possibility of mixing different substances in the sewer network, which form toxic gases, vapors or dense sediments, as well as spontaneous combustion and explosion when mixed with water or other chemicals, should be excluded. 3.31. Electrolytes, solutions, water and other liquids, before being released from the baths into the sewer, should be directed to special sedimentation tanks or treatment facilities for appropriate treatment. 3.32. Keep the work area clean and free from clutter. 4. Safety requirements in emergency situations 4.1. If acid or alkali gets on an open part of the body, it is necessary to wash the affected areas with water, and then neutralize:
4.2. In case of poisoning with acid vapors, the victim must be taken to fresh air and freed from clothing that restricts breathing, medical personnel with an oxygen bag should be called. Artificial respiration in this case is contraindicated. 4.3. In case of injury, poisoning and sudden illness, the victim should be provided with first (pre-medical) aid and, if necessary, his delivery to a healthcare facility should be organized. 4.4. When rotating parts of machines, slings, cargo hooks and other equipment capture parts of the body or clothing, give a signal to stop work and, if possible, take measures to stop the machine (equipment). You should not try to free yourself from the grip if it is possible to attract others. 4.5. In the event of a fire:
5. Safety requirements at the end of work 5.1. After work, wash off the transport trolley and containers from acid and alkali with a jet of cold water. Rinse boots, gloves and apron with water. 5.2. Tidy up the workplace, put the tools and fixtures in the tool box. 5.3. Take off overalls and other personal protective equipment and hang them in a specially designed place. 5.4. Wash hands and face with warm soapy water, rinse mouth and shower.
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