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1EuropeanAgencyforSafetyandHealthatWork–EU-OSHA67MAINTENANCEANDHAZARDOUSSUBSTANCES–MAINTENANCEINTHECHEMICALINDUSTRY1IntroductionTheEuropeanchemicalsindustryisoneofthebiggestindustrialsectorsandanimportantsourceofdirectandindirectemploymentinmanyregionsoftheEuropeanUnion,withaworkforceof1.2millionandsalesof€537billion(2007).Smallandmedium-sizedenterprises(SMEs)representasignificantshareoftheEUchemicalsindustry:96%ofallchemicalcompanieshavefewerthan250employeesandtheseareresponsiblefor28%ofallsalesand35%oftotalemployment.Asproducersofspecialities,SMEsareoftencustomersofthelargerentitiesinthesector,ratherthansuppliers[1].Thechemicalsindustryproducesawidevarietyofsubstancesandpreparationswhichareessentialforuseinaverybroadrangeofapplicationsinvirtuallyallsectorsoftheeconomy,including:basechemicals(petrochemicalsandderivatives,basicinorganicsandpolymers)usuallyproducedinlargevolumes;specialtychemicals(activeingredientsandco-formulantsforthepharmaceuticalsindustryandplantprotection,auxiliariesforindustrialprocesses,paints&inks,biocides,anddyesandpigments)usuallyproducedinlowervolumes;andconsumerchemicals(soapsanddetergents,perfumesandcosmetics).[1]Thechemicalindustryisoneoftheindustrieswiththemoststringentsafetyregulations.Regularrevision,servicingandmaintenanceworkisrequiredduetothehighstressplacedonequipmentbyexposuretoveryaggressivesubstances,hightemperaturesandpressures.Dependingonthesizeandtypeofplantsandoperationsconcerned,maintenanceofteninvolvescompleteshut-downs,however,specificproductionareamaintenanceandservicingoperationsaremorecommon.Whereassmall-scaleproductionlikethatofspecialitychemicalsisoftenrunasabatchoperation,large-scaleproductionismostlyrunascontinuousoperation.Inbothcasestheremaybevariouskindsoftechnicalsystemslikechemicalreactors(whichoftenhavetowithstandhighorlowtemperaturesandpressures),separationdevices(distillation,filtration,etc.),andfluidsystemsforliquidsandgases(pumps,valves,tanks),etc.Thecomplexnatureofchemicalplantsincreasestherisksformaintenanceworkers.Inaddition,theymaycomeintoclosecontactwithabroadvarietyofoftenhazardouschemicals.SomeexamplesofaccidentsmaybefoundintheEU-OSHApublication‘Maintenanceandoccupationalsafetyandhealth:astatisticalpicture’[2].Thise-factfocusesonthespecificrisksrelatedtovariousdangeroussubstancesthatmaintenanceworkersinchemicalplantsareexposedto,andgivessomebasicrecommendationsonhowtheseriskscanbetackled,includingsomegoodpracticeexamples.Acomplementarye-factdiscussesmaintenanceanddangeroussubstancesingeneral.https://osha.europa.eu/en/publications/e-facts/e-fact-66-maintenance-and-hazardous-substances/view2ExposuretosubstancesduringmaintenanceofchemicalinstallationsMaintenanceworkersin(petro-)chemicalplantsmaycomeintocontactwithawidevarietyofsubstances.Generally,threemajorsourcesofexposuremaybedistinguishedinchemicalplantmaintenance:theuseofhazardousproductsorsubstances;substancesthatareemittedasaresultofcertainactivities;and–mostcommonly–substancesthatmaybepresentinproductionfacilitiesthataremaintained.Maintenanceandhazardoussubstances–MaintenanceinthechemicalindustryEuropeanAgencyforSafetyandHealthatWork–EU-OSHA2SubstancesorproductsusedinmaintenanceInmostcases,maintenanceofchemicalplantsdoesnotinvolveahighuseofproductsorsubstances.Incleaningoperationsinparticular,waterisinfactthemostfrequentlyusedagen...