metal fume risk evaluation - esafetyline s/eei fall 2007... · metal fume risk evaluation how to...
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METAL FUME RISK METAL FUME RISK EVALUATIONEVALUATION
HOW TO TARGETHOW TO TARGETHOW TO TARGET HOW TO TARGET AIR SAMPLING AIR SAMPLING
IN ELECTRIC POWER PLANTSIN ELECTRIC POWER PLANTS
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Challenges for Industrial Health Challenges for Industrial Health T h i iT h i iTechnicians Technicians
►►Finding and measuringFinding and measuring high fumehigh fume►►Finding and measuringFinding and measuring high fume high fume exposure activities is difficult. exposure activities is difficult.
►►These activities are inherently sporadic, These activities are inherently sporadic, not continuous.not continuous.
►►Schedules are unpredictable.Schedules are unpredictable.W kfW kf tt ii►►Workforce Workforce may notmay not recognize or recognize or communicatecommunicate high fume exposures.high fume exposures.
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THE WRONG WAYTHE WRONG WAYTHE WRONG WAYTHE WRONG WAY
►►Pick a crew at Pick a crew at randomrandomrandom.random.
►►“Hey, can we “Hey, can we take some air take some air samples?”samples?”
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THE RIGHT WAYTHE RIGHT WAYTHE RIGHT WAYTHE RIGHT WAY
►►Inquire at top andInquire at top and►►Inquire at top and Inquire at top and bottom of bottom of organizationsorganizationsorganizations.organizations.
►►Look for highest Look for highest fume rates not justfume rates not justfume rates, not just fume rates, not just “welding” in “welding” in generalgeneralgeneral.general.
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HIGHEST FUME EXPOSURESHIGHEST FUME EXPOSURESHIGHEST FUME EXPOSURES HIGHEST FUME EXPOSURES OCURR DURINGOCURR DURINGOCURR DURINGOCURR DURING
THERMAL CUTTINGTHERMAL CUTTING►►AirAir--Arc cutting and gougingArc cutting and gouging►►Plasma Arc cuttingPlasma Arc cutting►►OxyOxy--Fuel “flame” or “oxygen” cuttingFuel “flame” or “oxygen” cutting►►OxyOxy Fuel flame or oxygen cuttingFuel flame or oxygen cutting►►Worst during Worst during demolition demolition oror teartear--downdown
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EXAMPLE: CrEXAMPLE: Cr--6 RESULTS ON 6 RESULTS ON 304 STAINLESS STEEL304 STAINLESS STEEL304 STAINLESS STEEL304 STAINLESS STEEL
►►AirAir--Arc Gouging =Arc Gouging = 10 x PEL10 x PEL►►AirAir Arc Gouging = Arc Gouging = 10 x PEL10 x PEL
Pl C ttiPl C tti 5 PEL5 PEL►►Plasma Cutting = Plasma Cutting = 5 x PEL5 x PEL
►►Compare to 309 stick weld = Compare to 309 stick weld = 1.5 x PEL1.5 x PEL
►►Other fumes follow similar pattern.Other fumes follow similar pattern.
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Why Is Cutting The Worst Case?Why Is Cutting The Worst Case?Why Is Cutting The Worst Case?Why Is Cutting The Worst Case?
►►Cutting melts Cutting melts ►►Cutt g e tsCutt g e tsand vaporizes and vaporizes more metal more metal faster thanfaster thanfaster than faster than welding.welding.
►► Paint, plating, Paint, plating, oil, or other oil, or other contamination contamination can be can be presentpresentpresent.present.
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Poor ventilation is common during cuts. Poor ventilation is common during cuts.
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Other dangers can overshadow fume safety.Other dangers can overshadow fume safety.
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Thermal CuttingThermal Cutting -- Worst CasesWorst CasesThermal Cutting Thermal Cutting Worst CasesWorst Cases
►►Copper Brass and BronzeCopper Brass and Bronze►►Copper, Brass, and BronzeCopper, Brass, and Bronze►►Nickel alloys (Inconel, Monel)Nickel alloys (Inconel, Monel)
H df i llH df i ll►►Hardfacing alloysHardfacing alloys►►Stainless steelStainless steel►►Manganese wear steelManganese wear steel►►Painted or electroplated steelPainted or electroplated steel►►Painted or electroplated steelPainted or electroplated steel►►Galvanized steelGalvanized steel
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Typical confined work area in hydro runner.Typical confined work area in hydro runner.
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What Not To Test; What Not To Test; Low Risk Cutting JobsLow Risk Cutting JobsLow Risk Cutting JobsLow Risk Cutting Jobs
►►Bare carbon steelBare carbon steelM h i l tti hi iM h i l tti hi i►►Mechanical cutting or machiningMechanical cutting or machining
►►GrindingGrinding►►GrindingGrinding
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NEXT HIGHEST FUME RISK:NEXT HIGHEST FUME RISK:CLADDING & CLADDING &
THERMAL SPRAYTHERMAL SPRAYW ldW ld l ddil ddi dd h df ih df i►►Weld Weld claddingcladding and and hardfacinghardfacing
►►ArcArc--SprayedSprayed coatingscoatings►►FlameFlame--SprayedSprayed coatingscoatings►►Commonly used inCommonly used in Fuel HandlingFuel Handling,, BoilersBoilers,,►►Commonly used in Commonly used in Fuel HandlingFuel Handling, , BoilersBoilers, ,
and and Hydro Rebuilds.Hydro Rebuilds.
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EXAMPLE: CrEXAMPLE: Cr--6 RESULTS FOR6 RESULTS FORCLADDING AND THERMAL SPRAYCLADDING AND THERMAL SPRAYCLADDING AND THERMAL SPRAYCLADDING AND THERMAL SPRAY
►► Flame and Arc Spray in Boiler = Flame and Arc Spray in Boiler = 10 x PEL10 x PEL►► a e a d c Sp ay o ea e a d c Sp ay o e 00
►►Weld Cladding, Inconel 622, Boiler = Weld Cladding, Inconel 622, Boiler = 5 x PEL5 x PELg, ,g, ,
►►Weld Cladding 309 stainless, Hydro = Weld Cladding 309 stainless, Hydro = 5 x PEL5 x PEL
►►Compare to 309 stick weld = Compare to 309 stick weld = 1.5 x PEL1.5 x PEL
►►Other fumes follow similar pattern.Other fumes follow similar pattern.
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Why Is Cladding & Spraying a Risk?Why Is Cladding & Spraying a Risk?Why Is Cladding & Spraying a Risk?Why Is Cladding & Spraying a Risk?
►► Large surfaceLarge surface►► Large surface Large surface areas covered areas covered very fast.very fast.
►►Usually applies Usually applies y ppy ppalloys high in alloys high in Cr, Ni, Mn, Cr, Ni, Mn,
d hd hand other and other heavy metals.heavy metals.
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WHO TO TEST DURING CLADDING WHO TO TEST DURING CLADDING AND SPRAYING?AND SPRAYING?AND SPRAYING?AND SPRAYING?
►►Specialty contractors are usually well trainedSpecialty contractors are usually well trained►►Specialty contractors are usually well trained Specialty contractors are usually well trained in proper PPE. Check that they use it.in proper PPE. Check that they use it.
►►Other nearby workers Other nearby workers may notmay not be trained or be trained or h PPE I l d th i t t lh PPE I l d th i t t lhave proper PPE. Include them in test plan.have proper PPE. Include them in test plan.
►►Boundary testing and access controls often Boundary testing and access controls often used to limit incidental exposures.used to limit incidental exposures.pp
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WELDING & BRAZINGWELDING & BRAZINGWELDING & BRAZING WELDING & BRAZING FUMESFUMESFUMESFUMES
►►Look for mostLook for most pounds used per hourpounds used per hour►►Look for most Look for most pounds used per hourpounds used per hour..►►Longest arcLongest arc--on times.on times.►►High risk alloys and Cr content.High risk alloys and Cr content.►►Worker head positionWorker head position►►Worker head position.Worker head position.►►Local ventilation.Local ventilation.
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More Pounds Per Hour Means Higher More Pounds Per Hour Means Higher F R tF R tFume RatesFume Rates
►►Mechanized welding has Mechanized welding has longer run times thanlonger run times thanlonger run times than longer run times than manual.manual.
►► Fumes from multiple Fumes from multiple welders working in one welders working in one area will add up.area will add up.
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HIGH RISK WELDING ALLOYSHIGH RISK WELDING ALLOYSHIGH RISK WELDING ALLOYSHIGH RISK WELDING ALLOYS
►►Nickel alloys (Inconel Monel)Nickel alloys (Inconel Monel)►►Nickel alloys (Inconel, Monel)Nickel alloys (Inconel, Monel)►►HardfacingHardfacing►►Stainless steelStainless steel►►Manganese wear steelManganese wear steel►►Manganese wear steelManganese wear steel►►Copper, Brass, and BronzeCopper, Brass, and Bronze
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Low Cr vs High CrLow Cr vs High CrLow Cr vs High CrLow Cr vs High Cr
►►Tends to becomeTends to become►►Tends to become Tends to become a problem at a problem at 22--1/4% Cr and 1/4% Cr and higher.higher.
►►Usually not a Usually not a problem at problem at
/ % C d/ % C d11--1/4% Cr and 1/4% Cr and lower.lower.
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Worker Head PositionWorker Head Positionk fk fBottom Worker of 2Bottom Worker of 2--man Teamman Team
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Worker Head PositionWorker Head Positionk fk fTop Worker of 2Top Worker of 2--man Teamman Team
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Typical Field Ventilation SystemTypical Field Ventilation System►►Bring in outside Bring in outside
air if possible.air if possible.pp
►►Removing heat is Removing heat is ggoften more often more valuable than valuable than removing fumes.removing fumes.
►►Move and adjust Move and adjust the system as job the system as job progresses.progresses.
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Fresh Air Trunk for WelderFresh Air Trunk for Welder
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Brazing FumesBrazing FumesBrazing FumesBrazing Fumes
►► Flux brazing Flux brazing ►► u b a gu b a gcreates more fume creates more fume than nonthan non--flux flux brazingbrazingbrazing.brazing.
►► Fluoride, bromide, Fluoride, bromide, or acid fumes areor acid fumes areor acid fumes are or acid fumes are possible with some possible with some types. types.
►►Don’t be afraid to Don’t be afraid to ask!ask!
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Effect of Job DurationEffect of Job DurationEffect of Job DurationEffect of Job Duration
►►Most maintenance jobs are very shortMost maintenance jobs are very short►►Most maintenance jobs are very short Most maintenance jobs are very short duration. Fume exposure tends to be self duration. Fume exposure tends to be self limitinglimitinglimiting.limiting.
►►Fume exposure can Fume exposure can dramatically increase dramatically increase during longer duration jobsduring longer duration jobsduring longer duration jobs.during longer duration jobs.
►►Crews and management may not adjust PPE Crews and management may not adjust PPE d/ til ti di ld/ til ti di land/or ventilation accordingly.and/or ventilation accordingly.
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WeldingWelding –– Higher Fume MethodsHigher Fume MethodsWelding Welding Higher Fume MethodsHigher Fume Methods
►►SelfSelf--shielded Flux Coreshielded Flux Core►►SelfSelf--shielded Flux Coreshielded Flux Core
►►GasGas--shielded Flux Coreshielded Flux Core
►►SMAW “stick electrode” over 1/8” SMAW “stick electrode” over 1/8” diameterdiameter
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What Not To Test;What Not To Test;What Not To Test; What Not To Test; Low Risk Welding JobsLow Risk Welding Jobs
►►GTAW or “Tig”, except for ozone.GTAW or “Tig”, except for ozone.
►►SMAW “stick” on carbon steel withSMAW “stick” on carbon steel with►►SMAW stick on carbon steel with SMAW stick on carbon steel with short duration.short duration.
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REVIEWREVIEW►► Look at Look at thermal cuttingthermal cutting first. That’s your highest first. That’s your highest
exposure potential.exposure potential.
►►CladdingCladding and and Thermal Spray Thermal Spray applications.applications.
►► Sort welding jobs by Sort welding jobs by processprocess and and alloyalloy; don’t ; don’t waste time testing low risk jobswaste time testing low risk jobswaste time testing low risk jobs.waste time testing low risk jobs.
►► Effect ofEffect of head positionhead position on test resultson test results►► Effect of Effect of head position head position on test results.on test results.
►► Effect ofEffect of local ventilationlocal ventilation on test resultson test results►► Effect of Effect of local ventilation local ventilation on test results.on test results.
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Q S O S?Q S O S?QUESTIONS?QUESTIONS?