Controlling Chemical Hazards

Chemical Mixing; Liquid and Dry

EXECUTION DOCUMENT CONTROL APPRO ACH R GS 102

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guidance to users rather than act as a
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users and situations, it presents
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Hazards
The mixing area provides an opportunity for exposure to chemicals and products at the point at which
powdered products or liquid additives are introduced to the operation. Typically this occurs through a cone
shaped venturi hopper. The narrow bottom section of the cone has a fluids circulating pipe passing through it
and a choke provides a jetting action within the pipe which draws the materials added into the fluid being
circulated. The products and the associated additives are usually handled manually at the hopper. This can
give rise to dust or splashing. Both of these conditions may be hazardous. More modern facilities enable
powdered products to be handled mechanically even to the point of removing and disposing of the packaging.
Liquid additives can be pumped into the hopper instead of manually poured. The handling of powdered
sacked products and liquid products from drums or cans, and the mixing of bulk powders such as barite, can
cause exposure. Primarily this will be inhalation exposure as there may be dust associated with the
movement of products in the storage area or with mixing products into the hopper. However, skin contact can
also occur, particularly with powdered materials.
Alternatively, products and additives can be handled in bulk form from pre-loaded containers and added to
the drilling fluid system from a remotely operated control zone, minimizing exposure at the rig site. Appendix
1 provides more detail about potential exposure to chemicals while mixing.
Access Control
Restrict access only to authorized staff that have been trained and equipped to work safely.
Equipment and Procedures
Select less hazardous additives if possible (e.g., low
silica content bentonite and barite, low aromatic content
base fluids for oil based mud systems).
Enclose the mixer as much as possible, and provide
seals on the lid and other access points.
Consider automating and enclosing mixing system to
eliminate need for direct worker contact with additives
(see GS 303 Containment).
If enclosure is impracticable use local exhaust ventilation
(LEV) hood that is positioned as close to the source of
the dust or vapor source as possible (see GS 302
Control Approach 2).
Airflow across the whole mixer top should be towards the
LEV and away from the workers adding materials.
Where possible, use lids on the mixer to contain dust and
vapors.
Where possible, locate the working area away from other
work areas to prevent exposure to other workers.
Discharge extracted air (from LEV) to a safe place away
from workers.

If LEV or enclosure is not practicable, respiratory protective equipment is required unless occupational
hygiene monitoring demonstrates visible dust, mist or vapor concentrations are less than 50% of
occupational exposure limits (see GS 304 Control Approach 4 and GS 305 Exposure monitoring).
Maintenance
Maintain the equipment as advised by the supplier/installer, in effective and efficient working order. Employee checklist for
Get information on the design performance of the ventilation equipment from the supplier. Keep this making the best use of
information to compare with future test results. the controls:
Visually check the ventilation equipment at least once a week for signs of damage.
Have the ventilation equipment examined and tested against its performance standard - generally at  Make sure the
least every year. ventilation system is
Keep records of all examinations and tests for at least five years. switched on and is
working.
Personal Protective Equipment
 Make sure the air
Respiratory Protective Equipment movement is across
NIOSH approved P-95 (or P-99 or P-100) with combination organic vapor cartridge (if hydrocarbons or away from your
also present) if no local exhaust ventilation or enclosed process unless occupational hygiene monitoring face, and try not to
demonstrates dust, mist or vapor concentrations do not exceed 50% of occupational exposure limit (see lean into the mixer
GS 304 Specialist and GS 305 Exposure monitoring). when adding
Self Contained Breathing Air: To be used when H2S may exceed 10 ppm (see GS007 Working with materials.
H2S & GS401 Selection and use of respiratory equipment).
 Look for signs of
Other Personal Protective Equipment damage, wear or
poor operation of
Personal H2S Monitor: To be worn at all times (see GS402 H2S Monitors).
any equipment
Fire Retardant Coveralls: To be worn at all times (see GS403 Fire Resistant Clothing).
used. If you find any
Chemical resistant gloves, clothing, boots and eye protection (goggles) are required if direct contact problems, tell your
with additives (see 400 Reducing skin contact and GS 404 Gloves). supervisor.
Cleaning and Housekeeping
 Do not carry on
Keep all work areas neat and free from debris. working if you think
Clean up chemical spills promptly (see GS 406 Spill response). there is a problem.
Training and Supervision  Make sure that
paper bags and
Employer responsibilities other waste
 Gather and provide safety data sheets on the chemicals that will be present at the workplace. material are not
 Use the Controlling Chemical Hazards Guideline to assist in defining the procedures and control drawn into the
approaches you need to follow to protect worker health and safety. ventilation duct.
Supervisor responsibilities  Wash your hands
 Ensure the availability of the required Guidance Sheets for chemical management. before and after
 Ensure the availability and use of appropriate protective equipment. eating, drinking or
 Complete and review with workers the chemical management process and the applicable Safety Data using the bathroom.
Sheets.
 Review safe work procedures with workers before they start work.  Clear up spills
immediately.
Worker responsibilities
 Wear appropriate personal protective equipment.  Use vacuum
 Follow safe work procedures. cleaning or wet
 Ensure spills and leaks are quickly cleaned up. mopping/sweeping
 Wash contaminated clothing before reuse. for solids. Contain
or absorb spills with
granules or mats.
Dispose of spills
safely.

 Use, maintain and

store any PPE
provided in
accordance with
instructions.

Further Reading and References

1. Enform - IRP Volume #14 - Non Water Based Drilling and Completions / Well Servicing Fluids http://www.enform.ca/publications/irps/nonwaterbaseddrilling.aspx
2 QEPA Literature Review of Oil Industry Worker Exposure http://qepa.com/documents/WorkerExposureFinal_002.pdf
3. IPIECA Drilling fluids and health risk management http://www.ipieca.org/?q=library&page=1&tid_1=12
Appendix 1 Mix area potential exposure to chemicals (exerpt from IPIECA Drilling fluids and health risk management)
General influencing factors: design and type of mix equipment; indoors or outdoors; space and layout of the work area; general or local exhaust ventilation;
health and safety culture of the workforce, e.g. PPE discipline; ambient temperature.

Task Purpose Exposure duration Type of exposure Influencing factors

Introducing ● Mixing through a venturi ● Variable, hours to days ● Drilling fluid system additives: ● Venturi hopper design
solid chemicals hopper inhalation and skin contact of ● Packaging type
to the drilling dust ● Bulk transfer tanks
fluid system ● Skin contact with contaminated ● Solid material characteristics
surfaces ● Volume to be mixed

● Direct to mix tank/pit
● Variable, several hours
● Drilling fluid system additives:
inhalation and skin contact of
dust
● Skin contact with contaminated
surfaces
● Splashing
● Mix system configuration
● Packaging type
● Solid material characteristics
● Volume to be mixed

● Through automated mixing ● Variable, several hours ● Normal operations, no dust/ ● Reliability of the system
system possibly days splashing exposure, as fully ● Suitability of products for use in
contained system the system
● Suitability of packaging

Introducing ● Mixing through a venturi ● Variable, hours ● Drilling fluid system additives: ● Venturi hopper design
liquid hopper skin contact with contaminated ● Ergonomics
chemicals to surfaces, potential for splashing ● Packaging type
the drilling ● Liquid material characteristics
fluid system ● Volume to be mixed

● Direct to mix tank/ pit ● Variable, hours ● Drilling fluid system additives: ● Mix system configuration
skin contact with contaminated ● Packaging type
surfaces, potential for splashing ● Liquid material characteristics
● Volume to be mixed

● Through automated mixing ● Variable, hours ● Drilling fluid system additives: ● Reliability of the system
system skin contact with contaminated ● Suitability of products for use in
surfaces the system
● Suitability of packaging

Handling ● Containment and handling of
packaging waste packaging materials,
sacks, big bags, drums,
intermediate bulk containers
● Hours, continuous during
mixing operations
● Drilling fluid system additives:
skin contact with contaminated
surfaces
● Dust and vapor inhalation from
handling waste
● Packaging type
● Chemical characteristics
● Chemical compatibility
● Waste collection, storage and
disposal methods

Storage of ● Sack and drum storage of ● Short term, intermittent ● Skin contact with ● Packaging type
chemical chemical additives to be contaminated surfaces ● Chemical characteristics
additives used in mixing process ● Dust and vapor inhalation ● Layout and design of
from handling damaged storage area
packaged materials
Manual ● Movement of sacks and drums ● Short term, intermittent ● Skin contact with ● Packaging type
handling of of chemical additives to and contaminated surfaces ● Chemical characteristics
chemical from mix area ● Dust and vapor inhalation ● Ergonomics
additives from handling damaged
packaged materials

Mechanical ● Movement of packaged ● Short term, intermittent ● Dust and vapor inhalation ● Packaging type
handling of chemical additives to and from handling damaged ● Chemical characteristics
chemical from mix area packaged materials
additives