The presentation is about hazard identification as against hazard assessment. The need to comply with all standard safety procedures as outlined by OSHA

1. HAZARD IDENTIFICATION
Carbon Dioxide, Ammonia, Dust, Water, Confined
space, Fire outbreak

2. Hazard
• “A hazard is any source of potential damage, harm
or adverse health effects on something or
someone.”

3. • HAZARD ASESSMENT VS HAZARD IDENTIFICATION

4. Hazard Assessment
Hazard assessments are simply a process of
identifying hazards, evaluating the risks
presented by those hazards, and managing the
risks of the hazards of the experiment to be
performed by incorporating appropriate hazard
controls into the experimental design process.

5. You can execute a hazard assessment by following
these simple steps:
1. List out each step of a process or task in the order
in which it is executed. This list can serve as the
outline of a standard operating procedure, or SOP.
2. Assess hazards that could occur during each step
of the task. List what could go wrong at each step,
classifying it by its likelihood, its severity, and its
detectability.

6. 3. Develop a means to eliminate, or at least restrict,
the potential of each hazard at each step in the task.
Know that there may be several potential hazards for
a single step. Methods of hazard control generally fall
into one of two classes: protection and prevention.

7. 4. Rewrite the list of steps for the task, and state the
safety protocols to be performed at each step. A
safety-oriented SOP will guide staff in the safest way to
perform their duties. The completed hazard
assessment and SOP should also be used to identify
which OSHA standards apply to each procedure.

8. Hazard Identification

9. Hazard Identification
• Hazard identification is part of the process used to
evaluate if any particular situation, item, thing, etc.
may have the potential to cause harm. The term
often used to describe the full process is risk
assessment:
• Identify hazards and risk factors that have the
potential to cause harm (hazard identification).
• Analyze and evaluate the risk associated with that
hazard (risk analysis, and risk evaluation).
• Determine appropriate ways to eliminate the hazard,
or control the risk when the hazard cannot be
eliminated (risk control).

10. • Overall, the goal of hazard identification is to find
and record possible hazards that may be present in
your workplace. It may help to work as a team and
include both people familiar with the work area, as
well as people who are not – this way you have
both the experienced and fresh eye to conduct the
inspection.

11. When to carry out Hazard Identification
Hazard identification can be done:
During design and implementation
• Designing a new process or procedure
• Purchasing and installing new machinery
Before tasks are done
– Checking equipment or following processes
– Reviewing surroundings before each shift

12. While tasks are being done
• Be aware of changes, abnormal conditions, or
sudden emissions
During inspections
• Formal, informal, supervisor, health and safety
committee
After incidents
• Near misses or minor events
• Injuries

13. How to detect hazards
• Look at all aspects of the work and include non-
routine activities such as maintenance, repair, or
cleaning.
• Look at the physical work environment,
equipment, materials, products, etc. that are
used.
• Include how the tasks are done.
• Look at injury and incident records.

14. • Talk to the workers: they know their job and its
hazards best.
• Include all shifts, and people who work off site either
at home, on other job sites, drivers, teleworkers,
with clients, etc.
• Look at the way the work is organized or done
(include experience of people doing the work,
systems being used, etc.).
• Look at foreseeable unusual conditions (for example:
possible impact on hazard control procedures that
may be unavailable in an emergency situation, power
outage, etc.).

15. • Determine whether a product, machine or
equipment can be intentionally or unintentionally
changed (e.g., a safety guard that could be removed).
• Review all of the phases of the lifecycle.
• Examine risks to visitors or the public.
• Consider the groups of people that may have a
different level of risk such as young or inexperienced
workers, persons with disabilities, or new or
expectant mothers.

16. Types of Hazards
A common way to classify hazards is by category:
• biological – bacteria, viruses, insects, plants, birds,
animals, and humans, etc.,
• chemical – depends on the physical, chemical and
toxic properties of the chemical,
• ergonomic – repetitive movements, improper set up
of workstation, etc.,

17. • physical – radiation, magnetic fields, temperature
extremes, pressure extremes (high pressure or
vacuum), noise, etc.,
• psychosocial – stress, violence, etc.,
• safety – slipping/tripping hazards, inappropriate
machine guarding, equipment malfunctions or
breakdowns.

19. Specific Hazards
• Carbon Dioxide
• Ammonia
• Water
• Confined Space
• Fire Outbreak
• Dust

20. Brewing Industry: CO2 Hazards

21. Carbon Dioxide
Colourless gas. Odourless. Will not burn.
Compresse gas. Contains refrigerated gas. May
explode if heated. CONFINED SPACE HAZARD. Can
accumulate in hazardous amounts in low-lying
areas especially inside confined spaces.
ASPHYXIANT. High concentrations can displace
oxygen in air and cause suffocation. May cause
frostbite.Carbon dioxide is used for the
carbonation of beverages.

22. • CO2 is the gas that gives the fizz to soft drinks
and sparkling wines. In breweries, CO2 is
recovered as a by-product of fermentation. As
high concentrations of CO2 are clearly
hazardous, most countries, have set
workplace exposure limits. Carbon dioxide
monitoring is essential for employee safety in
the brewing and carbonated drinks industry.

23. • Due to its molecular density, the gas typically
collects at the bottom of confined spaces,
including tanks and cellars, which could
eventually leak out and sink into floors. When
it sinks to the floor it can become dangerous
through forming invisible pockets.

24. Health Effects of CO2
Inhalation: Low concentrations are not harmful.
Higher concentrations can affect respiratory
function and cause excitation followed by
depression of the central nervous system. If less
oxygen is available to breathe, symptoms such as
rapid breathing, rapid heart rate, clumsiness,
emotional upsets, fatigue, nausea and vomiting,
collapse, convulsions, coma and death can occur.

25. • Skin Contact: Not irritating. Direct contact
with the liquefied gas can chill or freeze the
skin (frostbite). Symptoms of mild frostbite
include numbness, prickling and itching.
Symptoms of more severe frostbite include a
burning sensation and stiffness. The skin may
become waxy white or yellow. Blistering,
tissue death and infection may develop in
severe cases.

26. • Eye Contact: May cause mild irritation. Direct
contact with the liquefied gas can freeze the
eye. Permanent eye damage or blindness can
result.
• Ingestion: Not a relevant route of exposure
(gas).
• Carcinogenicity: Not known to cause cancer.

27. • Symptoms of mild CO2 exposure may include
headache and drowsiness. At higher
levels,rapid breathing, confusion, increased
cardiac output, elevated blood pressure and
increased arrhythmias may occur.
• Breathing oxygen depleted air caused by
extreme CO2 concentrations can lead to death
by suffocation.

28. Precautions to observe in CO2
• Employees should receive training and be
knowledgeable of the potential sources and
symptoms of exposure to CO2.
• The fermentation/ pressurized gas should be
discharged directly into the open air via a ring
main system, this will completely remove the
carbon dioxide from the contained space.

29. • If you are working near any sources of dry ice and
develop any of the symptoms of exposure, move to
an area of fresh air immediately, and report the
incident to your supervisor. (Freshair or oxygen is
the primary remedy for CO2 exposure).
• Do not enter areas where CO2 levels exceed 20,000
ppm until ventilation has been provided to bring
the concentration down to safe levels.
• Do not stand directly next to open bins that contain
dry ice or in vapors from these bins. Do not touch
dry ice or a bin containing dry ice.

30. • A release measurement should be conducted
using a suitable gas detector before entering a
confined space assessing if the CO2
concentration is within the acceptable
parameters.
• There are two forms of gas detectors, portable
and fixed which can be both be used in
breweries.

31. PPE to be used
• Eye/Face Protection: Wear chemical safety goggles.
(frost bite).
• Skin Protection: Always wear insulated protective
clothing, if contact with refrigerated gas is possible.
• Respiratory Protection:
• Up to 40000 ppm: (prts per million)
• (APF = 10) Any supplied-air respirator.
• (APF = 50) Any self-contained breathing apparatus
with a full facepiece.
• APF = Assigned Protection Factor

32. Brewing Industry: Ammonia Hazards

33. • Ammonia is a colorless, poisonous gas with a familiar
noxious odor. It occurs in nature, primarily produced
by anaerobic decay of plant and animal matter; and
it also has been detected in outer space. Some
plants, mainly legumes, in combination with rhizobia
bacteria, “fix” atmospheric nitrogen to produce
ammonia.
• idely used as a refrigerant in industrial facilities,
including breweries. Ammonia can be a health
hazard because it is corrosive to the skin, eyes and
lungs. It is a flammable vapor.

34. Health Effects of Ammonia
• High levels of ammonia can irritate and burn the
skin, mouth, throat, lungs, and eyes. Very high levels
of ammonia can damage the lungs or cause death.
Workers may be harmed from exposure to ammonia.
The level of exposure depends upon dose, duration,
and work being done.

35. Ammonia hazard information
Hazard class* Hazard statement
Gases under pressure, liquefied gas H280—Contains gas under pressure;
may explode if heated
Skin corrosion/irritation, category 1B H314—Causes severe skin burns
Serious eye damage/eye irritation,
category 1
H318—Causes serious eye damage
Acute toxicity, inhalation, category 3 H331—Toxic if inhaled
Hazardous to the aquatic
environment, acute hazard, category
1
H400—Very toxic to aquatic life
Hazardous to the aquatic
environment, long-term hazard,
category 2
H411—Toxic to aquatic life with long-
lasting effects

36. Confined Spaces
• An area large enough and so configured that an
employee can bodily enter and performed assigned
work, and Has limited or restricted means of entry or
exit and Is not designed for continuous occupancy.

37. • In confined space like tanks, workers can be exposed
to unsafe atmospheric conditions. Employees who
work in confined spaces face increased risk of serious
physical injury. Hazards involving a confined space
include entrapment, engulfment, and dangerous
atmospheric conditions. As a result, employees who
conduct work within confined spaces must be properly
trained.
What are the confined spaces in your brewery plant?

38. • Examples of confined spaces typically found in
breweries include bright tanks, fermenters, grain
bins, silos, mash tuns, kettles, yeast propagation
tanks, liquor tanks and trailers used for fresh or spent
grain. In addition, larger breweries may have sump
pits, utility vaults, water treatment tanks and other
confined spaces.

39. Confined Space Classification
• There are different categories of confined spaces:
• Permit Required Confined Space
• Reclassified Confined Space
• Alternate Entry Procedure Confined Space
• Not Classified as a Confined Space

40. • Many types of brewery confined spaces will contain
carbon dioxide and may also be oxygen deficient.
Other serious safety hazards could include powered
rakes, stir paddles, agitators, clean in place systems
(CIP), inlets to allow entry of liquids or grains and
other mechanical or physical hazards such as heat or
steam

41. CASE STUDY
• In April 2013, seven workers were killed in a tank that
was undergoing maintenance and cleaning at a plant in
Mexico City operated by Corona beermaker, Grupo
Modelo. It is believed that four victims were
maintenance contractors and three victims were other
Modelo employees. There are few details available on
the incident. It is speculated that the deaths were due
to “unspecified toxins” and that the three Modelo
employees had entered the tank in an effort to rescue
the other four contract employees. Mexican
authorities are reportedly investigating the incident.

42. • What lessons can we learn from the accident
involving corona brewery workers

43. • Where a confined space could pose a hazard to a worker,
OSHA requires several safeguards to ensure confined
space safety. Those include:
• Written Confined Space Permit Program: OSHA requires
a written program that, among other things, identifies
and evaluates the hazards that may be present, requires
testing the atmospheric conditions of a confined space,
and includes instructions for summoning rescue and
emergency services.

44. • Entry Permits: Employees must receive a confined
space entry permit, signed by the entry
supervisor, before performing work in a confined
space.
• Worker Training: Employers must provide all
necessary training for workers who may enter a
permit-required confined space.

45. DUSTS
• Dusts are solid particles ranging in size from
below 1 µm up to around 100 µm, which may
be or become airborne, depending on their
origin, physical characteristics and ambient
conditions.
• Occupational exposure of brewery workers to
organic dusts such as hops, barley, and
brewery yeast has the potential to change
respiratory function and immunological
status.

46. • Examples of hazardous dusts in the workplace
include:
• mineral dusts from the extraction and processing of
minerals (these often contain silica, which is
particularly dangerous); metallic dusts, such as lead
and cadmium and their compounds; other chemical
dusts, such as bulk chemicals and pesticides;
vegetable dusts, such as wood, flour, cotton and tea,
and pollens; moulds and spores.

47. • Dust arising from malt handling and
processing is an important hazard in breweries
because of its long-term effects upon the
mucous membranes when inhaled.

48. Dust Removal
• The best practice for avoiding a dust explosion is
thorough and regular housekeeping.
• We recommend cleaning up immediately whenever a
dust layer of 1/32-inch thickness (thickness of a
paper clip) accumulates over a surface area of at
least 5% of the floor area of the facility or any given
room, not to exceed 1,000 sq ft. Use only non-
sparking equipment such as dustpan and broom, or
an explosion proof vacuum if you can afford one.

49. Water
• Water is one of the most important raw
materials used in beer brewing.
• Water quality and its characteristics can
make the difference between a good beer
and a great beer. Different types of beer
need different types of water
characteristics. But first Water that is used
in great brewery’s needs to be:

50. • Fresh & Clean
• Free of odors (caused by source and Chlorine)
and Contaminates
• moderately hard and have low-to-moderate
alkalinity.
• If the water taste good then it will probable
make foe good tasting beer

51. WATER

52. What are the hazards associated with
water in a brewery?

53. • Slips and falls on walking surfaces:
• There is a lot of water used in the brewing
process, causing breweries to often have
slippery walking surfaces. Without proper
cleanup, the result can be overly wet floors—
making slips and falls nearly inevitable. The
brewing process also heavily relies on hoses to
move the brew from one tank to another. The
hoses are typically strung across the floor,
posing a trip or fall hazard.

54. • Boiling water, toxic cleaning chemicals, and
hazardous vapors are just some of the hazards
brewers may face on any given day. It’s
important that employees wear the right
equipment in these scenarios, . OSHA’s
standard for eye and face protection
maintains that employers provide the
appropriate gear when employees are
exposed to hazards from a variety of sources.

55. Types of Accidents Common to Breweries
Toxic Exposure
• Brewers often are exposed to hazard chemicals during
the beer making process. The use of ammonia
refrigeration exposes brewery workers to the release of
this toxic and flammable chemical. Carbon dioxide, a
byproduct of the beer making process, also can be
extremely dangerous to workers. Even the heavy
chemical cleaning agents required to sanitize the
equipment from the used water, hops, grains, yeast
and other beer ingredients can pose a toxic exposure
risk.

56. Equipment Accidents
• Dangerous equipment accidents may occur when
brewery machinery is not properly maintained or
operated. Brewery equipment such as fermenters,
bottling lines, grain silos, mash tuns and kettles must
be properly cleaned and serviced to create a safe
working environment for brewery workers. Brewers
must be trained in specific lockout and tagout
procedures to avoid the unexpected startup of brewery
equipment. An explosion of an overpressured vessel is
another type of brewery accident that occurs when
equipment is not carefully monitored.

57. Forklift Accidents
• Almost 100,000 forklift-related accidents, including
85 fatalities, take place each year around the world.
Breweries frequently use forklifts to transport raw
ingredients, move brewery equipment and lift
pallets and kegs. All fork lift drivers should receive
formal and practical instruction before operating
the fork lift.

58. Types of Injuries
• The Bureau of Labor Statistics reports the
number of nonfatal injuries resulting from
brewery accidents has increased by 57
percent in the last eight years. Some of the
most common types of injuries include burns,
back injuries and respiratory illnesses.

59. • Labor intensive brewery tasks such as lifting
heavy beer kegs or transporting grain bags can
result in physical injuries ranging from strained
muscles, broken bones and back and spinal
cord injuries. Wet floor surfaces can cause slips
and falls which led to broken bones, head
injuries including concussions or traumatic
brain injuries and bruises.

60. • Burns are another type of injuries common for
brewery workers. When vessels boil over with
hot liquids, workers are at risk for severe
burns that often require hospitalization. The
fermentation process can result in explosions
and implosions which also put brewery
workers at risk for burn injuries.

61. • Strains and sprains:
• Lifting, handling and moving heavy materials can
cause muscle strains and sprains. Brewery employees
regularly lift 50-pound bags of grain, fill and move
kegs that weigh up to 140 pounds and maneuver
heavy hoses. To protect employees, it is essential to
provide lifting and moving tools, as well as training
on proper lifting techniques and good ergonomics.

62. • Falls from heights:
• The brew kettle may be high enough off the floor
to make climbing a necessary task for employees
keeping an eye on the brew process and adding
ingredients. In small or new facilities, built-in safety
structures such as catwalks and attached ladders
may be limited. So employees might have to climb
a leaning ladder to peek into the vat and add
ingredients or operate hoses.

63. • Hazardous chemicals:
• There are several types of hazardous chemicals involved in
brewery operations. As with any facility, some cleaning
compounds and sanitizers are caustic or toxic. Even if the
cleaning fluid is food safe, it can be dangerous if it splashes
into an eye or on bare skin. There is also the need to work
with compressed gases, including carbon dioxide and
compressed nitrogen. To prevent these brewing ingredients
from leaking, they must be secured properly. Your safety
program should include personal protection equipment (PPE)
and lockout tagout (LOTO) permits. It’s also important to be
aware of confined space regulations and to have labels and
instructions on all hazardous chemicals.

64. CONCLUSION
All brewers should conduct periodic hazard
analysis in order to establish safety practices
that address the particular challenges found in
their brewery. Establishing a sound safety
program is an ongoing process that includes
recognizing hazards and learning how to
mitigate them.