by Margaret Ahrweiler

A critical and often overlooked component of a facility's safety plan is routine job-site equipment evaluations. Any facility with emergency eye wash and drench shower equipment should include evaluations as part of its standard operating procedure. A job-site evaluation consists of a walk-through of each workstation on a regular basis to ensure the right type of equipment is present and that it operates properly.

The evaluation criteria typically used in a walk-through are based on the ANSI/ISEA Z358.1 standard. This standard outlines specific requirements for emergency eye wash and drench shower equipment related to installation, test procedures, performance, maintenance, training, and use. Those assigned to administer equipment evaluations should be educated on the ANSI standard and must be given the proper tools to perform the testing requirements and document their findings.

Determining Proper Emergency Equipment

The first step in evaluating a job site is to determine whether existing equipment meets the facility's needs, or if none exists, what type and how many emergency fixtures are needed. Because a job site can be relocated or the applications can change, different equipment may be necessary. Proper equipment should be selected based on potential hazards to different parts of the body--usually eye, face, or body specific.

For example, if a job involves grinding metal and workers are not wearing proper eye protection, there is potential for metal shavings to get into their eyes. In this scenario, a plumbed or portable eye wash unit would be needed on site. If the entire body were exposed, a drench shower would be used. It is important to note that drench showers are not intended for flushing eyes because the velocity and volume of the water released could cause additional eye injury.

In many cases, an eye or eye/face wash with drench shower is required. Generally a combination unit is the best solution, because this type of fixture allows the user to drench eyes, face, and body simultaneously.

Climate should also be a consideration. If fixtures are kept outdoors or in a cooler room where temperatures drop below freezing, incoming supply lines and equipment should be installed so they will not freeze. For these applications, heat-traced units typically are used, or fixtures with a water supply valve that is placed below the frost line.

Water Supply, Temperature, and Drainage

After determining the type of emergency fixture, it is important to evaluate the incoming water supply line, water temperature, and drainage.

According to ANSI, each type of equipment has minimum flow requirements; eye wash is 0.4 gpm, face wash is 3 gpm, and drench shower is 20 gpm. All units must operate at a minimum water pressure of 30 psi.

To ensure the fixtures meet these requirements, the incoming water supply pipe size (IPS) should be checked. Minimum IPS recommendations are a half-inch for eye and eye/face washes, one inch for drench showers, and one and a quarter inches for combination showers with eye and/or face washes. If the IPS is below the minimum, the unit may not have enough water pressure to meet flow requirements.

The ANSI standard for water temperature is tepid, defined as lukewarm. ANSI also specifies that a medical adviser should be consulted to determine the appropriate temperature range for specific job-site applications, because the water temperature could cause further damage to the eyes and skin. Temperature extremes can prevent users from drenching for the full 15 minutes, as required by ANSI.

Water temperature can be controlled in several ways. Thermostatic mixing valves blend hot and cold water to a specific set point. Instantaneous electric water heaters run one water source through coils to achieve the same result. Steam heaters are yet another option.

Drainage is an important but often overlooked consideration when emergency equipment is installed. If water pools under the drench area, the contaminated water could cause additional damage to the user's feet and legs or harm those who are supporting the injured worker. Electrical shocks pose another risk.

Proper drainage should take the amount of water that will be released during the 15-minute flush into account. Based on ANSI minimum flow requirements, eye washes will release 6 gallons, eye/face washes will release 37.5 gallons, and drench showers will release 300 gallons. It is important to note contaminated waste should be disposed according to local codes and ordinances.

Location, Location, Location

At each job site, the location and pathway to the unit are critical. Emergency eye wash and drench shower equipment should be installed within 10 seconds of the hazard with no obstructions. Based on average walking speed, this equates to 50 to 100 feet. If very caustic acids are a hazard, the equipment should be placed immediately adjacent to where exposure could occur.

Because emergency equipment is typically used infrequently, the area around the fixture often becomes used for extra storage or as a temporary parking place for the forklift. These are obstructions that prohibit an injured worker from getting to the equipment quickly. Other obstructions include steps, walls, or doors. If permanent objects in the pathway cannot be removed, the best option is to move the equipment to a more directly accessible location.

If the area is tight or some obstructions simply can't be eliminated, employees should be trained on how to get the injured worker to the equipment. ANSI requires that the emergency area to be well lighted, and each fixture should have a highly visible sign for quick identification.

Testing, Performance, and Maintenance

The final and most important step in a job-site equipment evaluation is making sure the equipment works when someone needs it. The value of having the right type of fixture installed at the right location is greatly diminished if it does not perform properly. If a unit malfunctions in an emergency, the result could be permanent injuries that might have otherwise been avoided.

ANSI mandates that plumbed equipment be tested weekly to verify proper operation. Weekly testing also flushes the water line to eliminate the possibility of iron, lime, and mineral deposits building up from stagnant water. Portable self-contained equipment should be tested and maintained according to the manufacturer's instructions.

An evaluation checklist can be a helpful tool during a job-site evaluation. This type of form is a comprehensive way to check off the ANSI performance requirements by equipment type. This written documentation is handy for future reference or OSHA inspections. Other tools for evaluations should include an eye wash test gauge, tape measure, thermometer, shower tester with bucket, and watch with a second hand.

Here are a few tips for using these testing tools:

• Use a watch to ensure the appropriate flow rate and velocity. When testing drench showers, the shower tester and bucket are also used.
• Make sure the unit activates in one second or less and that the ball valve opens the water supply and stays open until it is manually turned off.
• Check tepid water temperature using a thermometer.
• Be sure spray heads have a sufficient spray pattern to simultaneously flush both eyes, using the eye wash test gauge.
• Use a tape measure to verify proper distance of drench shower and eye wash components, to be sure equipment meets ANSI specifications.

After testing each job site, if any of the equipment is not performing properly, the manufacturer of the equipment should be contacted immediately to provide solutions to correct the problem. If components such as dust caps, identification signs, push handles, or bowls are missing or broken, replace them immediately. Finally, complete an inspection tag after inspection and affix it to the unit.

You never know when an emergency could happen. Proper evaluation and testing will make sure the emergency fixtures are always ready . . . just in case.