Guide to Eyewash Testing and Maintenance
Eyewashes can be critical in the seconds after an accident. It is important to regularly check that they are functioning properly so they are ready for those rare emergencies. Check out PE Facts to learn how to maintain eyewashes and keep eyes safe from hazardous solutions!
Introduction
If a facility has dangerous corrosives present, it is required that drenching equipment is readily available. This equipment could include an eyewash, eye/face wash, shower or combination eye/face wash shower; which one you choose depends on the risk to the employee of possible exposure to the chemical. For example, the facility should have a drench shower available if there is a possibility of the employee having more than just their eyes or face exposed to the chemical. This requirement can be found in the OSHA Code of Federal Regulations (CFR) 1910.151(c).
OSHA refers to the American National Standards Institute (ANSI) Z358.1 standard for the requirements that all portable and plumbed emergency eye, eye/face wash and emergency shower equipment need to meet. This includes construction, testing, location, water pressure, flow requirements, operation and maintenance, among others. There will be an ANSI seal of approval on the equipment to indicate that the manufacturer’s product meets these requirements.
Emergency eyewash stations and showers are usually not used often, so it is important to make sure that they are working properly for those few emergency situations. Studies have shown that cleansing eyes immediately after injury or chemical splash is absolutely crucial to minimizing damage. This is why it is imperative to keep eyewash stations and showers in good condition, if not, you could suffer severe consequences.
The American National Standards Institute (ANSI) created a standard especially for eyewashes and showers. Standard, Z358.1-2004, states that “emergency eyewash and shower equipment shall be located on the same level as the hazard, have un-obstructed access, and require not more than 10 seconds to reach.” Z358.1-2004 also outlines precise locations and flow rates for these devices—a section of the standard that is often overlooked is the testing and maintenance of these devices and the training of employees in their proper use.
Common Problems
Recently the Fendall Company (manufacturer of emergency eye-care products) conducted a survey study of about 200 manufacturing facilities in the U.S. to determine the quality of their eyewashes. They found that many of the facilities lacked a sufficient number of units. Even worse was that many of the units already installed were in a very poor condition. Over one third of the stations inspected did not function properly or were completely inoperable; almost all of the problems were directly related to poor maintenance. Here are some of the most common problems the survey found:
- Nozzles clogged, broken or missing
- Activating valve inoperable
- Improper water pressure—too high or low
- Low fluid levels in self-contained eyewashes
- Foreign particles in bowl or basin
- Nozzle dust covers not installed
In addition, the survey showed that the cleansing liquid was of poor quality in over 50% of plumbed and gravity-fed eyewashes. Of these samples:
- 60% had visible debris or discoloration
- Nearly two-thirds had total plate counts exceeding 500 colony forming units per milliliter (cfu/ml)
- 58% of units tested for microbial contamination contained the psuedomonas bacteria 1
- 10% had a too high or too low pH level
1 The study tested only for this bacterium.
Flushing Fluids
The quality of flushing fluid is very important but is, somehow, often overlooked. The presence of dirt or other foreign particles, or unacceptable levels of microorganisms can cause even more damage to the eyes. Furthermore, debris can reduce or restrict the flow of the fluid by partially blocking or clogging the nozzle.
Flushing fluid should be clean, clear, and visibly free of any dirt or debris. The presence of contaminants or discoloration is clear evidence of poor fluid quality in the supply line or in the water source. Contaminants can enter the eyewash fluid through openings in the unit or through a biofilm on the inside of the station.
The biological activity of a fluid is measured by its plate count. A total plate count of 100 cfu/ml or less is considered potable, while values higher than 100 cfu/ml but lower than 500 cfu/ml are questionable. Any count higher than 500 cfu/ml is considered to be poor quality. This is an indication to immediately sanitize gravity-fed eyewashes or plumbed units. It is important to disinfect eyewashes when total plate count is too high because injured eyes are more prone to infection when microorganisms are present in the flushing fluid.
There are also specific requirements concerning the flow of fluid to eyewashes and showers in the ANSI standard. Each eyewash and shower must meet the minimum flow rate for the equipment to work properly, they must pass OSHA inspections, and they must provide relief in the case of an accidental splash. There are different flow requirements for each specific piece of equipment. For 15 minutes of flush Plumbed and Self-Contained eyewashes require a minimum flow of 0.4 gallons per minute (GPM). Plumbed Eye/Face washes must meet a minimum flow of 3.0GPM, and combination showers and drench showers must have a minimum flow of 20 GPM. All eye/face washes must be set up in a way that the fluid can flush the eyes and face simultaneously. The ANSI standard recommends annual inspection of all eyewash units to ensure that flow requirements are met.
pH Levels
Tears typically have a pH of 7.4 with some buffer capacity. The flushing fluid in an eyewash should ideally have a pH close to 7.4 along with a saline solution, similar to the natural fluid of the eye. If the pH of the flushing fluid is too high or low it may not be suitable to use in an emergency eyewash solution.
ANSI Standards
It is important to follow the recommended requirements for testing and maintenance of eyewash stations set forth in Z358.1-2004 in order to be sure that they will be ready when you need them. The American National Standard offers minimum requirements for eyewashes and showers to operate effectively.
The requirements for testing and maintaining any eyewash, eye/face wash, or shower is based on the manufacturer's instructions as well as ANSI recommendations. Manufacturer's instructions usually state that all devices “should be inspected, tested and recorded weekly”. Owner manuals should be referred to for specific guidelines. The ANSI standard Z358.1 5.5.2 states that “plumbed eyewashes, eye/face washes and showers...should be activated weekly for a period long enough to verify operation and ensure that the flushing fluid is available”. Obviously, self-contained eyewashes cannot be activated weekly because it would use up valuable solution. For these units, ANSI recommends visual inspections to see if there is any dirt or debris contaminating the fluid.
Plumbed and self-contained eyewashes should also be examined and maintained according to the manufacturer's instructions. This includes shielding nozzles and flushing fluid from airborne impurities. It is also sensible to check the activation device and fluid level of self-contained eyewashes weekly. Flushing fluid should be changed periodically. Table 1 supplies replacement schedules for eyewash flushing fluids.
Table 1
| Flushing Fluid Type | Recommended Replacement Schedule |
|---|---|
| Tap water only | Weekly. |
| Tap water mixed with a manufacturer's preservative | Test mixture to identify bacterial loads and determine a maintenance cycle. Manufacturer's recommend fluid changes of three to six months. |
| Tap water mixed with a factory-prepared liquid concentrate plus an additive | Same as above. |
| Factory-sealed cartridges | Expiration date of cartridge. |
Preservatives
Fluid replacement schedules recommended by manufacturers are only guidelines. Preservatives are used in flushing fluid to control levels of bacteria but they are not universally effective. Preservative's performance can be affected by a biofilm in the station or by the bacteria originally present in the water. Self-contained eyewash units should be completely drained and cleaned before refilling.
While performing the annual inspection, flow meters and other measuring devices can be utilized to ensure units are working properly with the right amount of flow.
Summary
You should always examine and test any eyewash station to ensure its reliability. Establish a regular maintenance program to identify any problems or concerns. The manufacturer's operating manual and ANSI Z358.1-2004 can be consulted for more information about maintenance operations and performing test procedures.
Commonly Asked Questions
Q. Who should be trained on the proper use of emergency eyewashes and showers?
A. According to the ANSI, all employees who have the potential to be exposed to hazardous materials should be trained to use the eyewash and shower devices. Specific things that should be addressed are how to activate the systems, the location of the units and how to properly maintain them.
Q. How do you effectively flush eyes that have been contaminated??
A. Hold eyelids wide open and roll the eyeballs so that fluid flows over all surfaces of the eye and under the eyelid.
Q. Is there an alternative to repeatedly changing gravity-fed eyewash solutions?
A. Yes. Factory-sealed cartridges containing eyewash solutions are available. These products are considerably easier to maintain and have shelf lives that far exceed preservative solutions.
Sources for More Information
29 CFR 1910.151(c)Please Note: The information contained in this publication is intended for general information purposes only. This publication is not a substitute for review of the applicable government regulations and standards, and should not be construed as legal advice or opinion. Readers with specific questions should refer to the cited regulation or consult with an attorney.
