Health, Safety and Workplace Environment Unit - Handling Anhydrous Ammonia

This report focuses on the safe handling of anhydrous ammonia in a food manufacturing industry. It includes observations, risk assessments, and interviews with facilities and general managers. The report provides recommendations to improve safety practices and comply with OHS laws.

Running head: HEALTH, SAFETY AND WORKPLACE ENVIRONMENT UNIT
Health, Safety and Workplace Environment Unit
Name of the University:
Name of the Student:
Author Note:

1HEALTH, SAFETY AND WORKPLACE ENVIRONMENT UNIT
Executive Summary
Ammonia belongs to the class 2 of the regulated dangerous goods; it has received a class 8 foe
being corrosive. While handling anhydrous ammonia, proper protective clothing must be worn
that will cover the whole body including the face. Eyewash and a safety shower must be
available nearby. While handling one must avoid contact with clothing and skin and eyes; and
one must not breathe mist or vapor. The main findings of the assessment revealed that the
employees requires more training and education regarding increasing the awareness and proper
handling of the anhydrous ammonia cylinders and the awareness regarding the personal hygiene
and usage of personal protective equipment. General manager must be more concerned about the
employees regarding the way employees carry out their work. In the monthly maintenance
report, the safety reports and the chemical registers. General manager must work in a way so as
to comply with the legislation, and keep a track of the penalties, incident of risks, and safe
workplace. A closer integration is required between the facilities manager and the head office.

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Table of Contents
Introduction......................................................................................................................................3
Discussion........................................................................................................................................3
Background and location.............................................................................................................3
Purpose and scope........................................................................................................................4
Manufacturer’s safe handling instructions-SDS..........................................................................4
Task observation and risk assessment.............................................................................................6
Observation and findings.............................................................................................................6
Discussion of results........................................................................................................................7
Interviews....................................................................................................................................7
Conclusion.......................................................................................................................................9
Recommendation.............................................................................................................................9
References......................................................................................................................................11
Appendix........................................................................................................................................13

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Introduction
Exposure to the hazardous chemicals that are commonly used in the workplaces often
result in to the long- and short-term health effects like the disorders in the liver, kidney, lung
functioning, skin rashes and poisoning. About 1/4th of the Australian employees use the toxic or
the hazardous chemicals like flammable gases and liquids in their workplace. Hazardous
substances exist in different forms such as dust or solid, liquid, powder, and gas. The hazardous
substance can be in diluted or in pure form. There is a legal obligation for both the manufacturers
of the hazardous substances and the importers of the hazardous substances to include Material
Safety Data Sheets (MSDS) and warning labels along with the products. It is however important
to note that the MSDS is now known as Safety Data Sheets as per the new occupational Health
and Safety Regulations (Safe Work Australia, 2018). Ammonia is a colorless and a clear liquid
and it is found throughout the water, air, soil, in animals, humans and plants. Ammonia is also
found in majority of the industrial and household cleaners. The workers that are exposed to high
levels of ammonia have the high chances of burning their eyes, lungs, throat, skin, mouth. It has
been found that exposure to very high levels of ammonia can lead to the damage of the lungs and
cause death as well. Exposure to high levels of ammonia depends on the work done, duration and
the dose (Ablis.business.gov.au, 2018). The study here is a basically done through observation
and it is being carried out along with the risk assessment. Handling and storage were assessed
according to the code of practice, interviews and manufacturers safety data sheets. The report is
limited to a single site in a food manufacturing industry. The problem identified is a site-specific
problem. In this report only one chemical will be assessed due to the several concerns raised
against it, ammonia. The report be structured to provide recommendations that will reduce the
hazard
Discussion
Background and location
The report will be focused on a food manufacturing industry, named x. This food
manufacturing industry has several buildings that has both p manufacturing and storage site.
After the food is manufactured it is then transferred to the Storage Area which uses ammonia as
a refrigerant. Maintenance of the Storage Area is done by the onsite facilities manager.

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Purpose and scope
Through a senior management team this report has been commissioned at the head office.
It was a request of the facilities manager to investigate on the several issues of irritation and skin
burns due to the leakage of ammonia from the storage refrigerant pipes. The report will be
presented to the senior management team considering the current practices that are resulting into
injuries and subsequent recommendations to eliminate these problems. The report will consider
the code of practice as an assessment guide. The leakage of ammonia from the storage pipes is a
cause of concern and along with it is a subject of risk assessment. Refrigerant systems will be
observed, assessed and the final data will be recorded. It will be done finally assessed with the
safety data sheets of the manufacturers and code of practice.
Manufacturer’s safe handling instructions-SDS
According to the WHS Australia, ammonia is classified as a hazardous substance. Also,
according to the Australian Code for the Transport of Dangerous Goods by Road and Rail (ADG
Code), ammonia is specified as dangerous and classified for the physiochemical hazards (Mott,
2014).
CSBP limited is a company in Western Australia that supplies anhydrous ammonia for
the food manufacturing industry X. As per the GHS classification, ammonia is a category 2
flammable gas; it is a liquified gas as gases under pressure category; category 1B for the skin
irritation/corrosion; category 3 for the acute toxicity, inhalation; category 1 for the acute aquatic
hazard; and category 3 for chronic aquatic hazard. Hazard statements: flammable gas (H221);
may explode if heated, contains gas under pressure (H280); causes eye damage and skin burns
(H314); toxic if inhaled (H331); very to the aquatic life (H400); has long lasting effects and is
harmful to the aquatic life (H412) (csbp.com.au, 2018).
The following are the handling and the storage measures and procedures for anhydrous
ammonia:
 Ammonia belongs to the class 2 of the regulated dangerous goods; it has received
a class 8 foe being corrosive. While handling anhydrous ammonia, proper

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protective clothing must be worn that will cover the whole body including the
face. Eyewash and a safety shower must be available nearby. While handling one
must avoid contact with clothing and skin and eyes; and one must not breathe
mist or vapor.
 Not to touch the surface that has been ice on the surface of the storage containing
anhydrous cylinders. If skin somehow sticks to the surface of such a storage
container then one must thaw it with lukewarm water. However, failure to do so
will result in frostbite and serious injury.
 It is mandatory to add anhydrous ammonia to plenty of water in order to minimize
the generation of splashes and ammonia vapor.
 One must not smoke near the area that has storage and handling of anhydrous
ammonia or sites that are associated with the equipment and pipework.
 One must not touch the damaged or the spilled containers without wearing the
proper protective gears or equipment.
 After storage or reuse, one must wash their hands and change their clothes and
change the personal protective equipment if they are found to be contaminated.
 Storage must be done in accordance with the Australian Standard AS 2022 which
is a SAA anhydrous ammonia code and it is about anhydrous ammonia storage
and handling (csbp.com.au, 2018).
 The cylinders must be stored in place away from direct sunlight, heat, protected
from weather, ventilated area, dry and cool place. When cylinder is stored in bulk,
then such cylinders must be painted white so that it will reflect sunlight. There is
a chance of explosion if there is a nearby source of intense heat.
 The leaks present on the anhydrous ammonia cylinders can be checked through a
Sulphur dioxide test bottle.
 The surrounding areas of the equipment and storages of anhydrous ammonia must
be done according to the Australian standards of the hazardous areas.
 Oxidizing agents like brominating agents, chlorinating agents and hypochlorite,
along with the mineral acids and halogens must be stored away from the
anhydrous ammonia.

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 Anhydrous ammonia is highly corrosive to zinc, tin, copper, aluminum and their
alloys (csbp.com.au, 2018).
Task observation and risk assessment
The task of risk assessment was carried out on 10th September at 11 am. The risk
assessment was carried out after wearing the personal protective equipment in order to test the
any leakage in the storage area of anhydrous ammonia cylinders. Anhydrous ammonia is
required in the storage of the food after they are manufactured. The storage area was checked
with a sulfur dioxide test bottle.
Observation and findings
The following are the good practices that are found during the assessment procedure:
Good practices:
 A sign was placed in the in the storage area which has clear mention of the
presence of anhydrous ammonia cylinders.
 Other than anhydrous ammonia no other chemicals are stored in close proximity
of the anhydrous ammonia cylinders.
 The anhydrous ammonia was stored in the cylinder that were manufactured by the
original manufacturers.
 The anhydrous ammonia cylinders are well marked with the hazardous symbols.
 The safety data sheets are clearly visible on the wall which is written in English.
 The anhydrous ammonia cylinder is labelled properly according to the safe work
Australia criteria and GHS.
 The storage area has well placed signs signifying the do’s and don’ts.
 The storage area has proper provisions of ventilation that are in accordance with
the safety guidelines.
 When new cylinders are transferred in to the storage area, guidelines are
followed.
poor practices:
 The worker exposure to the ammonia is for elongated periods.

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 The workers when work in the storage area failed to wear the personal protective
equipment.
 The workers did not wear long sleeves when working with the empty anhydrous
ammonia cylinders.
 The facemask and the gloves are removed hurriedly and the workers do not wash
their hands in a proper way and this made the contaminants to stay with the
clothes and comes in contact with their body.
Discussion of results
As per the evidences that were gathered during the assessment, it can be concluded that
the safe handling procedures are adhered to. It has been seen that the employees are following
the strict order to reporting any incident. However, the employees are not stringently following
the rules pertaining to wearing personal protective equipment for safety purposes. The
employees did not follow the procedures when they are working with the empty cylinders of
anhydrous ammonia. The employee are carrying out the tasks in a hurriedly and especially they
are always removing the protective equipment in a hurriedly and this is main reason they are
getting contaminated. Although the storage places have proper ventilation still the ammonia
gases get leaked and the workers that work in the storage areas often complained about the
irritation and skin burns. Even though the signage and the storages are placed properly, however
the cylinders are not properly mentioned about when they are last checked, expiry.
Communication and signage are strong and the location of the first aid kits are placed and
marked properly along with the emergency information.
Interviews
The following information was revealed after interviewing the facilities manager.
 Facilities manager said that sometimes there is a huge pressure on the workers to
deliver a specific number of tasks.
 Although the company supplied the workers with the necessary equipment.
However, wearing them properly was not a big issue for the facilities manager.
 The facilities manager was not conscious enough of the need to wash the hands
after every task.

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 The facilities manager opined that the handling practices were proper and
adequate, while further discussion revealed that the handling could have been
improved.
 Facilities manager also suggested that an external contractor that will look after
the storage section of manufacturing plant. This will free up the time and the
supervisory role of the facilities manager.
 Facilities manager has agreed that he has experienced minor skin burns on the
legs, hands and arms. However, he considers them to be an occupational risk due
to the operating environment.
 Facilities manager has advised that he did not receive the employer health
monitoring at the regular intervals.
The following is revealed after interviewing the general manager of the manufacturing
company:
 The general manager was not aware of the safe handling procedures regarding the
handling of the anhydrous ammonia cylinders is not adhered by the employees.
However, he has mentioned that he has personally has not witnessed the task
being carried out. This is found to be a major flaw and is not in accordance with
the OHS law which clearly says that the head of a company or an organization is
responsible for the safety of the workers in the workplace.
 General manager did a general inspection of the area, however he said that he
relied on the facilities manager to properly and regularly inspect the storage area.
 General manager has said that he had not promoted the safe work culture
sufficiently among the workers.
Findings sourced from the interviews
 The main finding is that the employees requires more training and education
regarding increasing the awareness and proper handling of the anhydrous
ammonia cylinders and the awareness regarding the personal hygiene and usage
of personal protective equipment.
 General manager must be more concerned about the employees regarding the way
employees carry out their work.

9HEALTH, SAFETY AND WORKPLACE ENVIRONMENT UNIT
 In the monthly maintenance report, the safety reports and the chemical registers.
 General manager must work in a way so as to comply with the legislation, and
keep a track of the penalties, incident of risks, and safe workplace.
 A closer integration is required between the facilities manager and the head
office.
Conclusion
From the above discussion it can be concluded that, Exposure to the hazardous chemicals
that are commonly used in the workplaces often result in to the long- and short-term health
effects like the disorders in the liver, kidney, lung functioning, skin rashes and poisoning. . The
workers that are exposed to high levels of ammonia have the high chances of burning their eyes,
lungs, throat, skin, mouth. It has been found that exposure to very high levels of ammonia can
lead to the damage of the lungs and cause death as well. Exposure to high levels of ammonia
depends on the work done, duration and the dose.
Recommendation
The following are the recommendation and with the targeted completion dates:
Recommendation Responsible person Target completion date
Elimination of the old cylinders of
anhydrous ammonia from the storage
area.
Facilities manager 1/9/2018
Substitution of the anhydrous
ammonia with other less toxic gases
like carbon dioxide.
Supervisor, facilities
manager and general
manger
4/9/2018
Providing training to the staffs
including both the permanent and the
non-permanent, along the safe
handling procedures
facilities manager
and supervisor
10/9/2018
Ensuring that the personal protective
equipment is readily accessible and is
in good condition.
facilities manager 15/9/2018

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Enforce and provide the wearing of
the protective gear which operating in
the storage section.
facilities manager 19/9/2018
The anhydrous ammonia cylinder
must be checked regularly and the
dates of checking should be written on
the cylinders.
facilities manager 24/9/2018
The workers that are handling the
anhydrous ammonia cylinder must
wash their hands.
facilities manager 30/9/2018
Health monitoring of the employees at
regular intervals
facilities manager
and supervisor
6/10/2018
Foster a culture of safety among the
employees through interaction with
facilities manager
General manager 12/10/2018

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References
Ablis.business.gov.au. (2018). ABLIS | Enabling business. Retrieved from
https://ablis.business.gov.au/service/wa/australian-new-zealand-standard-as-nzs-2022-
anhydrous-ammonia-storage-and-handling/30955
csbp.com.au (2018). SAFETY DATA SHEET Ammonia (Anhydrous). [online] csbp.com.au.
Available at: https://www.csbp.com.au/docs/default-source/msds---products/ammonia-
ammonium-nitrate-products/msds_ammonia-(anhydrous).pdf?sfvrsn=38 [Accessed 17
Sep. 2018].
Dittrich, E. (Ed.). (2015). The Sustainable Laboratory Handbook: Design, Equipment, and
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safety data sheets (MSDSs) for engineered nanomaterials. Journal of Chemical Health
and Safety, 19(5), 1-8.
Mott, J. R. (2014). How to leave hydrocarbons in the ground. In Practical Responses to Climate
Change Conference 2014(p. 11). Engineers Australia.
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pelletizing industry. Indian journal of occupational and environmental medicine, 21(2),
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Safe Work Australia. (2018). Model Code of Practice: Managing risks of hazardous chemicals in
the workplace. Retrieved from https://www.safeworkaustralia.gov.au/doc/model-code-
practice-managing-risks-hazardous-chemicals-workplace
Schulte, P. A., Pandalai, S., Wulsin, V., & Chun, H. (2012). Interaction of occupational and
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102(3), 434-448.
Wang, Q., Mei, Q., Liu, S., & Zhang, J. (2018). Analysis of Managing Safety in Small
Enterprises: Dual-Effects of Employee Prosocial Safety Behavior and Government
Inspection. BioMed research international, 2018.

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Zala, N., & Kavishvar, A. (2012). Respiratory morbidity due to ammonia exposure among the
employees of a urea manufacturing industry located in western part of India. Indian
journal of occupational and environmental medicine, 16(3), 142.

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Appendix
Figure 1: Safety data sheet of anhydrous ammonia