Document 65p3Q2LVMLX6kaoZzm3yJE04d

INDUSTRIAL HYGIENE RULES RULE NUMBER IH-001 DATE: REPLACES RULE NUMBER: 1992 January 01 1-000 OF DATE(S) 82-12-28 RE; INDUSTRIAL HYGIENE PROGRAM Policy Statement Maintenance of a healthy workplace in order to protect each employee from potentially harmful agents in the working environment is a basic premise underlying Rockdale Operations. This is achieved by: Periodic evaluations of the workplace for early detection of environmental conditions that might prove detrimental to employee health. Institution of appropriate controls to minimize employee work exposures to potentially harmful conditions, in accordance with good industrial hygiene practice. Training employees to recognize the potential health hazards of their jobs and the means of avoiding undue exposure. e Assessing and recommending personal protection devices and providing instructions for their use and care. e Active Industrial Hygiene support of plant Safety and Health Steering Committee and the Departmental Safety and Health Committees. e Cooperation with local, state, and Federal government agencies charged with employee health protection so as to aid in the development of sound and effective standards and the development of common goals. Elements of Rockdale Operations' Industrial Hygiene Program e Respiratory Protection Program - Rockdale Operations has developed a Respiratory Protection Program designed to protect employees from undue exposure to airborne contaminants. A summary of this program is included in the Industrial Hygiene section of the Rockdale Operations Safety Manual and -is identified as Rule 1-002. Additional details are contained in Rockdale Operations Respiratory Protection Manual. ALCOA HQ 001541 INDUSTRIAL HYGIENE RULE IH-001 - INDUSTRIAL HYGIENE PROGRAM Revised 1992 January 01 Page 2 Hearing Conservation Program - Rockdale Operations has developed a comprehensive Hearing Conservation Program to protect employees from hearing loss due to exposure to occupational noise. The details of this program are included in Rule 1-004 in the Industrial Hygiene section of the Rockdale Operations Safety Manual. e Hazardous Materials Control - A procedure has been developed for early identification of hazardous materials at Rockdale Operations in order to ensure the safe use of these materials. Details of this procedure are given in Rule 1-006 in the Industrial Hygiene section of the Rockdale Operations Safety Manual. Additionally, Rule 1-003 describes the procedures to be used in disposing of wastes containing asbestos and Rule 1-005 deals with disposal of empty containers. Rockdale Operations Industrial Hygiene Survey contains a listing of materials used at the plant, the departments which use them, and a brief discussion of any associated hazards. e Urinary Fluoride Survey - Rockdale Operations conducts urinary fluoride surveys in order to monitor employee exposures to fluoride generated in the potroom work area. The surveys are done in accordance with the procedures given in Alcoa's Urinary Fluoride Survey Manual. Sample collection and analysis is done Industrial Hygiene Department. Feedback counselling of participants is done by the Department and Industrial Hygiene. by the to and Medical e Ionizing Radiation Control - Rockdale Operations has a program designed to protect employees from overexposure to ionizing radiation. The program includes: A. Maintaining an up-to-date of all ionizing radiation devices on the plant site and ensuring that all such devices are properly licensed by the Texas Department of Health. B. Ensuring that all ionizing radiation devices are properly labelled and that appropriate warning signs are displayed in the areas where the devices are used. -- C HQ 001542 INDUSTRIAL HYGIENE RULE IH-001 - INDUSTRIAL HYGIENE PROGRAM Revised 1992 January 01 Page 3 C. Ensuring that all ionizing radiation devices are inspected at prescribed intervals and that records of such inspections are maintained. D. A film badge program to monitor the exposure of employees working with ionization radiation devices. Items A, B, and C are the responsibility of the Senior Safety Engineer - Power. Item D is administered by the Medical Department. Schedules for Testing and Training Schedules for Testing are available from the Senior Industrial Hygiene Technician. Schedules of Training are available through the Training Management System which also provides a record of such training. The following pages are outlines of training programs which are available. HQ 001543 INDUSTRIAL HYGIENE RULE IH-001 - INDUSTRIAL HYGIENE PROGRAM Revised 1992 January 01 Page 4 HEARING CONSERVATION I. Objective: to insure that employees at Rockdale Operations do not suffer hearing loss due to exposure to occupational noise. II. Training Program Outline A. How the ear works B. Identification of Noise Hazards 1. Noise level surveys 2. Personal exposure sampling C. Control of noise exposure 1. Engineering controls 2. Administrative controls 3. Personal protective equipment -- show styles available at Rockdale D. Audiometric Testing E. Education F. OSHA/MSHA Standards G. Audio-visual Presentation III. Questions and Answers HQ 001544 INDUSTRIAL HYGIENE RULE IH-OOI - INDUSTRIAL HYGIENE PROGRAM Revised 1992 January 01 Page 5 PCB. SAFETY TRAINING I. Objective: training Rockdale. to ensure that employees are properly and equipped to handle PCB's found at II. Training Program Outline A. What are PCB's -- Where do they come from? B. Health effects of PCB exposure C. Routes of PCB entry into the body D. Personal protective equipment E. Regulations governing the use, storage and disposal of PCB's III. Questions and Answers HQ 001545 INDUSTRIAL HYGIENE RULE IH-001 - INDUSTRIAL HYGIENE PROGRAM Revised 1992 January 01 Page 6 RADIATION SAFETY TRAINING I. Objective: to ensure that employees are not exposed to harmful levels of ionizing radiation. II. Training Program Outline A. Types of radiation and characteristics of each B. Types of radiation devices found at Rockdale C. Personal monitoring program - review results with participating employees D. Discussion of Regulations a. allowable dose b. requirements for posting warnings and notices c. licensing and registration requirements E. Handout describing sources of annual radiation dose III. Questions and Answers HQ 001546 INDUSTRIAL HYGIENE RULE IH-001 - INDUSTRIAL HYGIENE PROGRAM Revised 2992 January 02 Page 7 RESPIRATORY PROTECTION cii > ( w A. Statement of Policy 1. Plant objective 2. OSHA/MSHA requirements - c atX. t f / ~J) L-w / -k\ hr? -> ' 5/=> B. Fundamental Respiratory Anatomy and Physiology 1. Entry 2. Mode of Travel 3. Basic Working Unit of the Lung C. Measurements of Toxic and Nuisance Atmospheres 1. Particulates 2. Gases D. Particulate Atmospheres 1. Types 2. Physiological Reactions E. Gaseous Atmospheres 1. Types 2. Physiological Reactions F. Types of Available Respirators 1. Disposable (a) 8706 (b) 8710 (c) 9910 (d) 9920 2. Rubber Face Piece Respirators (a) AD 50 and 60 Series 3. Self-contained breathing apparatus (SCBA) (if applicable) G. Fit-testing (if applicable) HQ 001547 HQ 001548 INDUSTRIAL HYGIENE RULES RULE NUMBER IH-002 DATE. REPLACES RULE NUMBER: 1992 January 01 1-001 OP OATElSI. 88-04-21 RE: ROCKDALE OPERATIONS RESPIRATORY PROTECTION PROGRAM ** ' * , , '/ Statement of Policy Ljfrs */;/!- t-rw- CA Rockdale Operations has developed a Respiratory Protection Program which will protect the employee while engineering design of equipment is being implemented. It is understood by Company management that the use of respiratory protection devices is permitted by OSHA/MSHA only when these engineering control methods are not feasible or are not completely effected, during the period that engineering control methods are being implemented, or in those cases of emergencies. A vt K/v' Selection Respirators have been selected on the basis of hazards to which the worker is exposed and will provide adequate respiratory protection against the particular hazard for which they are designed in accordance with the standards established by competent authorities. A list of areas and jobs requiring respiratory protection is attached. Training The user shall be instructed and trained in the proper use of respirators and their limitations. Ttainll*f stall include qsslitattasfetatataefcing of all employees whose job requires the use of or who voluntarily elect to wear air purifying respirators. Because of the wide variation in the degree of ^^ protection caused by the presence of facial hair, employees with 'responsibility of the department superintendent to ensure that T'" employees receive appropriate training. Respirator Assignment Nearly all of the respirators used at Rockdale are disposable types. Non-disposable respirators, where required, should be assigned to workers for their exclusive use. HQ 001549 ALCOA INDUSTRIAL HYGIENE RULE IH-002 - ROCKDALE OPERATIONS RESPIRATORY PROTECTION PROGRAM Revised 1992 January 01 Page 2 cleaning. Maintenance and Storage Non-disposable respirators shall be regularly inspected and cleaned by the user. Those used by more than one person (Scott Air-Paks, Sca-Paks and supplied air hose masks) shall be thoroughly cleaned and disinfected after each use. Storage Respirators shall be stored in a designated^ container in a convenient, clean, and sanitary location. / >^v ^ i-i. ^ ; c /- . -. p}* c, Compressed Air Breathing Devices Compressed air breathing devices such as air-supplied hoods, whitecap helmets, and airline respirators will be serviced and stored by users. Self-Contained Breathing Devices Self-contained breathing devices will be stored t# serviced by fir(W alt gt(TO guard' House. The only exceptions are those emergency devices strategically located around the plant. These emergency devices will be checked monthly by the guards and will be turned in for servicing after each use. Employees who are required to wear self-contained breathing devices must be fit tested annually. Employees with facial hair which interferes with the face piece seal cannot use self-contained breathing devices. Inspection Hon^dJ^^sablerespirat^s used routinely uhaH be inspected bp worn or deteriorated parts are found, the respirator shall be turned in for repair. Filters and cartridges shall be replaced each day or more often if necessary. Each respirator must have all the parts as designated by the manufacturer to be acceptable for use. Work Area Surveillance Appropriate surveillance of work area conditions and degree of employee exposure or stress shall be maintained on a periodic basis as established by Industrial Hygiene guidelines. Cartoon* moBesMtommieMH are used to check CU-content of each plant air Compressor. Concentrations in exeomno9^3^ppm will cause lnitoWrrmHTr the compressor involved. _ HQ 001550 INDUSTRIAL HYGIENE RULE IH-002 - ROCKDALE OPERATIONS RESPIRATORY PROTECTION PROGRAM Revised 1992 January 01 Page 3 Medical Considerations Persons should not be assigned to tasks requiring use of respirators unless it has been determined that they are physically able to perform the work and use the equipment. The Company physician shall determine what health and physical conditions are pertinent. The respirator user's medical status will be reviewed anmsally at the time of the annual physical examination. Insuring Compliance Employees will be expected to comply with Respiratory Protection rules as with any other safety rule and will be subject to normal enforcement procedures. Program Evaluation v>cRegular inspection and evaluations shall determine the continued ' effectiveness of the program. Audits shall be performed on a periodic basis. ReC91T<3K?ePin<l (s v* r*jt t h o? cfc fit >""***- >'<-*/' vt >*- The following records will be maintained as part of the Rockdale Operations Respiratory Protection Program: 1. Respiratory am g with eflpl'Uj ee1 a signature* 2. Record of and 3. Record of d 'Will be maintained in the Program Manual A copy of the Respiratory Protection, Proacfta i& included in each depaHflSfflf's copy of the RdflRKTe Operations Safety Manual. . ,\iCAL ^ r^? HQ 001551 INDUSTRIAL HYGIENE RULE IH-002 - ROCKDALE OPERATIONS RESPIRATORY PROTECTION PROGRAM Revised 1992 January 01 Page 4 Areas and/or Joh Requiring Respiratory Protection 1. Ore Shed - Basement - Dust - 3M 8710, 3M 8715, 3M 9900, 3M 9906, 3M 9916 AO 57A Cartridge, Moldex 2200, Scott 642D filter. 2. Ingot Plant - Skim loading - Skim dust - Air supplied helmet with powered air purifier. 3. Dust Collector Bag Changing - A. Entering and blowing down dust collectors in preparation for bag-changing - Air-supplied hood. B. Removing bags - 3M 8710, 3M 8715, 3M 9900, 3M 9906, 3M 9916, AO 57A Cartridge, Moldex 2200, Scott 642D filter. 4. Changing Chlorine Tanks - Ingot Plant - Chlorine gas - AO 53A Cartridge, 3M 7252 Cartridge, Scott 642AG Cartridge, Emergency Escape Only. R&M in a Chlorine environment requires a Scott Air-Pak. 5. Electrical Maintenance work inside precipitators - DustScott Type C supplied air hose mask with Scott Sca-Paks for emergency escape. 6. Confined Spaces - Plantwide - Low Oxygen - Scott Air Pak if Oj is below 19.58. Needs to parallel to confined space JSA. 7. Paint Spraying - Maintenance - Blasting grit dust - Airsupplied hood. 3M 8709 (isocyanates): 3M Easi Care 5000 Series for organic vapor with 5010 paint spray prelifter, 3M Easi-Air 7000 Series with 7251 organic vapor cartridge, 7256 paint spray prefilter. 8. Sandblasting - Maintenance - Blasting grit dust - Airsupplied hood. 9. Carbon Plant - Flue wall gunniting - Silica - AO 57A Cartridge, 3M 8710, 3M 9900, 3M 9906, 3M 9916, Moldex 2200, Scott 642D filter. HQ 001552 INDUSTRIAL HYGIENE RULE IH-002 - ROCKDALE OPERATIONS RESPIRATORY PROTECTION PROGRAM Revised 1992 January 01 Page 5 10. Carbon Plant - when performing jobs listed below - Coal tar pitch volatiles - 3M 8715, 3M 9900, 3M 9916, 3M 9920, AO 57A Cartridges, Moldex 2200, 3M 5000 Series with 7251 Cartridge and 7258 filter. Dumping mix from mix spreader (M5) e Cleaning mixers, mixer doors, mixer slide gates, mixer vent pipes e Cleaning choke-up above presses e General clean-up on mixer floor e General clean-up above presses e Cleaning dust collector pipes SC 2 and SC 7. e Changing mixer dust collector bags e Unloading pitch and pitching up - Bldg. 52 11. Potlining - Dumping pot shells - nuisance and Fluoride dust - 3M 8710, 3M 8715, 3M 9900, 3M 9916, AO 57A Cartridge Dustfoe 66, Moldex 2200, Scott 642D filter. 12. Potlining - Dumping mixer and installing mix - Coal tar pitch volatiles - AO 57A Cartridge, 3M 8715, 3M 9900, 3M 9916, 3M 9920, Moldex 2200, 3M 5000 Series with 7251 Cartridge and 7258 filter. 13. Potlining and Utility - Air lancing - metal fumes - airsupplied hood, AO 5057/6057, 3M 9920. 14. Potlining - Installing Superex insulation - Silica - 3M 8710, 3M 8715, 3M 9900, 3M 9916, AO 57A Cartridge, Moldex 2200, Scott 6420 filter. 15. Rodding Room - Digging and relining induction furnacesilica - Air-supplied helmet, 3M 8710, 3M 8715, 3M 9900, 3M 9906, 3M 9916, AO 57A Cartridge, Moldex 2200, Scott 6420 filter 16. Potrooms - Baking pots - Coal tar pitch volatiles, total particulate - AO 57A Cartridge, 3M 5000 series with 7251 Cartridge and 7258 filter, 3M Easi Care for organic vapors with prefilter. 17. Potrooms - TCC crews in T-51 lines when covering carbon or performing any task using air for cleaning - total dust and fluoride dust - AO 57A Cartridge 3M 8710, 3M 8715, 3M 9906, 3M 9916, Moldex 2200, Scott 642D filter HQ 001553 INDUSTRIAL HYGIENE RULE IH-002 - ROCKDALE OPERATIONS RESPIRATORY PROTECTION PROGRAM Revised 1992 January 01 Page 6 9916 RESPIRATOR Rockdale Operations is now stocking the 3M 9916 disposable respirator. This respirator is an update of the 9906 blue respirator that we presently use. The features include a collapse-resistant shell for greater reliability in heat, a redesigned nose cushion for improved wearer comfort, and an exhalation valve for relief of warm moist air from the face of the wearer. It is NIOSH/MSHA approved for dusts and mists up to ten times the permissible exposure limit, or the applicable OSHA limit, whichever is lower. 3M recommends this respirator for nuisance level acid gas relief. Typical gases that the 9916 could be used for are: Hydrogen fluoride (below the current OSHA PEL of 3 ppm) Sulfur dioxide (below the current OSHA PEL of 2 ppm) Hydrocarbon vapors (below current OSHA PELs) Nuisance levels are those below the permissible exposure limit for the particular gaseous contaminant. The 9916 is not to be used for paint spray, welding fumes or any other fumes, gases, or vapors; asbestos or sandblasting. This respirator does not supply oxygen. In test subjects, the 9916 lasted two to three and even eight times longer than the 9906. Duration will be highly dependent on the tasks being performed. At any time when breathing becomes difficult, a taste or smell is detected, leave the contaminated area, discard and replace the respirator. As a reminder, at Try * fur- an employee wears a respirator, voluntarily or mandated, they are to be tested. This is required by OSHA and Alcoa policy. This or any other respirator shall not be worn with beards or other facial hair that prevents direct contact between the face and the edge cf the respirator. If there are any questions, you may contact the Rockdale Operations Safety and Industrial Hygiene Department. HQ 001554 INDUSTRIAL HYGIENE RULES RULE NUMBER. IH-003 DATE: REPLACES RULE NUMBER: 1992 January 01 1-002 OF OATE(S) 87-08-07 REt ASBESTOS WASTE DISPOSAL CONTROL Asbestos-containing products used at Rockdale have been reduced in number in recent years as substitutes containing no asbestos have been found. There are, however, a few items still in use. The purpose of this rule is to identify these products and restate the procedure to be followed when disposing of them after removal from service. Asbestos Products at Rockdale 1. Garlock gasket material. 2. Valve packing. 3. Transite potroom fume duct sections. 4. Brake linings. 5. Pipe insulation installed before the changes to fiberglass insulation was made. 6. Furnace insulation in Bldgs. 34 and 90 may contain asbestos. The new furnaces in Bldg. 401 contain no asbestos insulation. Unless it can be positively established that no asbestos is present, demolition of furnace linings must be conducted as though asbestos were present and asbestos waste disposal procedures must be followed. Method of Disposal Items 1. 2. 3. and 4 These items are bonded and do not become friable to the extent that they might become airborne and result in an asbestos fiber concentration in the air in excess of the standard. It is, therefore, permissible to dispose of them in normal plant trash containers. Items 5 and 6 Unless it is definitely known that the insulation to be removed is non-asbestos, the material in question will be treated as asbestos. Any asbestos removal done at Rockdale Operations will be done by an approved contractor. HQ 001555 ALCOA INDUSTRIAL HYGIENE RULE IH-003 - ASBESTOS WASTE DISPOSAL CONTROL Revised 1992 January 01 Page 2 Contractors will be permitted to dispose of waste asbestos in a designated section of Alcoa's Class II Landfill. Disposal must be coordinated with the Construction Department so that arrangements can be made to cover the waste with six (6) inches of soil within twenty-four hours. Any waste placed in the area must be in containers approved for asbestos disposal. HQ 001556 HQ 001557 INDUSTRIAL HYGIENE RULES RULE NUMBER; DATE: REPLACES RULE NUMBER: _________TH-00A___________1992 January 01 ______1-003 OF OATE(S). 82-12-15 RE; HEARING CONSERVATION PROGRAM Objective It is Alcoa's policy to prevent hearing loss due to occupational exposure to noise. Employee enpoeures should not exceed 85 decibels A-scale (dBA), as an eight-hour tine-weighted average. To obtain this goal, reduction of excessive exposures must be accomplished by engineering or administrative controls, where feasible, and hearing protection, otherwise. In addition, an effective Hearing Conservation Program must be established whenever exposures exceed 85 dBA, as an eight-hour time-weighted average. The Rockdale Hearing Conservation Program includes the following elements: identification of noise hazards in new facilities and equipment, noise surveys, hearing protection, engineering controls, audiometric testing, investigation of significant threshold shifts and employee training. Responsibilities Engineering 1. Engineering management shall assure that noise controls are properly considered in the selection/development of new facilities and equipment. -- It is Alcoa's policy that noise exposures from modernized facilities and new equipment should not exceed 85 dBA, as an eight-hour average. This requirement is waived only when technical or economic infeasibility can be demonstrated and documented. -- The Alcoa Noise Control Worksheet (SP-488^) shall be completed and submitted with capital expenditure "Request for Authorization" (instructions are contained in Alcoa Engineering Standard 30.3.3). A copy of the completed form should be submitted to the Safety/Industrial Hygiene Manager. HQ 001558 ALCOA INDUSTRIAL HYGIENE RULE IH-004 - HEARING CONSERVATION PROGRAM Revised 1992 January 01 Page 2 -- Earth moving machinery, trucks, tractors, personnel, carriers, sweepers, mobile vacuum cleaners, fork lift trucks, and other industrial vehicles shall be purchased, leased, or rented whenever possible, in accord in Alcoa Engineering Standard 30.3.2. Departmental Management 1. Departmental management shall assure that employees are not exposed to noise greater than 85 dBA as an eight-hour average. Noise exposures shall be controlled by engineering or administrative methods, where feasible, and otherwise by the enforcement of hearing protection for specific job activities or in designated plant areas. Areas and jobs where eight-hour TWA noise exposure can be expected to exceed 85 dBA are included in Appendix A. 2. Departmental management shall assure that each employee assigned to a Job where the noise exposure may exceed 85 dBA, as an eight-hour average, is properly trained in the health effects of noise, audiometric testing, noise hazard of their work, the proper use of hearing protection, OSHA noise regulations and the provision of the Hearing Conservation Program. shall be repeated amraelly as indicated in Appendix D. Industrial Hygiene 1. The Rockdale Hearing Conservation Program is administered by the Safety/Industrial Hygiene Department. 2. The Senior Industrial Hygiene Technician shall evaluate the noise exposure for each job classification at Rockdale Operations. Where appropriate, engineering controls, administrative controls and/or hearing protection to reduce employee noise exposures to acceptable levels will be recommended. 3. The Senior Industrial Hygiene Technician shall investigate the noise exposure and use of hearing protection by employees with moderate or repeated significant threshold shifts. 4. The Safety/Industrial Hygiene Department shall administer the employee training program in Hearing Conservation. Medical Department 1. The Medical Department shall provide for baseline and HQ 001559 INDUSTRIAL HYGIENE RULE IH-004 - HEARING CONSERVATION PROGRAM Revised 1992 January 01 Page 3 periodic audiometric testing of all employees. Employees exposed above the 85 dBA criteria shall be tested at least annually. -- Audiometric testing, a form of medical surveillance, serves as an early warning of developing hearing disability which may be caused by many factors including noise, mechanical damage, infection and disease. -- Each audiogram is interpreted by a professional audiologist and/or otologist. 2. Employees with significant threshold shifts shall be counselled and notified in writing by the Medical Department as described in Appendix C. A significant threshold shift is warning that a change in hearing which, if left uncorrected and allowed to repeat over a period of time, could lead to a hearing impairment. 3. The Medical Department will fit -ell- insert type hearing ].> Uitest sin and provide employees with instructions for their proper use. Hearing protectors used at Rockdale are listed in Appendix B. sjcN'-' , flit) HQ 001560 INDUSTRIAL HYGIENE RULE IH-004 - HEARING CONSERVATION PROGRAM Revised 1992 January 01 Page 4 AREAS AND JOBS SUBJECT TO HEARING PROTECTION RBQUIRJE Areas Over 85 dBA, 8 Hr, TWA 1. Atomizer - Bldg. 401 (outside acoustical enclosure) 2. Atomizer - Bldg. 402 3. Boiler House - Bldg. 66 (outside acoustical enclosure) 4. Compressor House - Bldg. 27G 5. Ingot Plant - Bldg. 34 6. Properzi - Bldgs. 90 and 91 - Furnace and Mill Areas 7. Rodding - Bldg. 32 - West of Push-off Station 8. Green Carbon Area - Bldgs. 54 and 56 - Ball Mill Area 9. Bldg. 58 - Platform . 10. Press Room - Bldg. 54 11. Below A-398 Units - Lines 5f 7 and 8 12. Below Line 6 Precipitators 13. Below A-446 Units - Bldgs. 160, 162 and 164 14. Scrubber Water Pump Room - Bldg. 76X HQ 001561 INDUSTRIAL HYGIENE RULE IH-004 - HEARING CONSERVATION PROGRAM Revised 1992 January 01 Page 5 APPEHPIK A - continued AREAS AND JOBS SUBJECT TO HEARING PROTECTION REQUIREMENTS Jobs Over 85 dBA 1. Rowelling Siphons - Potrooms 2. Blowing Off Carbon with Compressed Air - Potrooms 3. Blowing Off Anode Bus with Compressed Air - Potrooms 4. Blowing Off Deck Plates with Compressed Air - Potrooms 5. Cleaning Floors with Compressed Air - Potrooms 6. Melting Buttons Off Anode Bus 7. Operating any Pneumatic Hammer or Impact Tool or Wrench 8. Operating Chambersberg Hammer - Bldg. 44 9. Operating or Working within Forty (40) Feet of Supersucker 10. Digging Pots with Pneumatic Digger 11. Operating Car Shaker - Bldg. 52 12. Unloading Precipitator Catch - Bldg. 19A 13. Operating Friction Joiner - Bldg. 32F 14. Cleaning Butts with Chipping Gun - Potrooms 15. High Pressure Shower Cleaning Unit HQ 001562 INDUSTRIAL HYGIENE RULE IH-004 - HEARING CONSERVATION PROGRAM Revised 1992 January 01 Page 6 APPENDIX A - continued AREAS AND JOBS SUBJECT TO HEARING PROTECTION REQUIREMENTS Vehicles Over 85 dBA 1. Any Holt Lift V80D Forklift 2. Any Walden 4000 Front End Loader 3. Any Walden 6000 Front End Loader 4. Hyster Forklift - Loading Pad 5. Silent Hoist Forklift - Properzi 6. Payloader - Scrap Metal Pickup 7. Trackmobile 8. Taylor 520 Forklift - Loading Pad 9. Tow Tractor for Hauling Precipitator Dust 10. Any Caterpillar Forklift 11. Silent Hoist Tractor for Carrying Carbon Blocks 12. Any Tennant Sweeper 13. All Clark Tractors 14. International 515 Front End Loader 15. Erickson Platform Truck for Hauling Brick 16. Kalamazoo Scooter with Welding Unit On 17. Kalamazoo Scooter with Goodall Starter Running 18. Towmotor Fork Truck 19. Ford Farm Tractor 20. Case 75 Backhoe 21. Rosco Vibrat Roller 22. Dreiser 8K Concrete Saw _ HQ 001563 INDUSTRIAL HYGIENE RULE IH-004 - HEARING CONSERVATION PROGRAM Revised 1992 January 01 Page 7 APRBfBIX-B HEARING PROTECTION AVAILABLE AT SAFETY CENTER Safety Center Stock Nuaber QB2 (Quiet Band) HL070-6 QB2 (Replaceable Pad for Above) HL070-7 EAR (Disposable) ER070-301 EAR (with Cord) ER070-31 Air Soft (with Cord) HL070-4 EAR - Ultrafit (with Cord) ER070-4004 Quiet (with Cord) HL070-2 Ear Muffs (Noise Foe) MS070-2 HQ 001564 INDUSTRIAL HYGIENE RULE IH-004 - HEARING CONSERVATION PROGRAM Revised 1992 January 01 Page 8 APPENDIX C Locations: Rockdale Operations Test Date: 1991 December 15 Dear MRS. JANE DOE: Recently you had your hearing checked in the Medical Department and the results indicate that there has been a decrease in your hearing ability. This diminished ability in hearing may be due to several factors: aging, medication or noise. Although you are not currently exposed to excessive amounts of noism, in your job, te prevent further hearing changes, you are encouraged to wear hearing protection while working around noisy off-the-job equipment such as tractors and chain saws or while participating in noisy hobbies, such as target shooting. He will be rechecking your hearing in the next few months to determine if your hearing has stabilized. If you have questions regarding this letter, or if you have questions at any time concerning your hearing, please do not hesitate to call the Medical Department. Thank you for participating in Alcoa's Hearing Conservation Program. Very truly yours, LOCATION MEDICAL DEPARTMENT Soc. Sec. No. 000-000-0001 Department No. 001 HQ 001565 INDUSTRIAL HYGIENE RULE IH-004 - HEARING CONSERVATION PROGRAM Revised 1992 January 01 . Page 9 APPENDIX C - continued Location: ROCKDALE OPERATIONS Test Date: 1991 December 15 Dear MR. J. H. DOE: Recently you had your hearing checked in the Medical Department. The results of that check indicate that your hearing ability has decreased. This diminished ability in hearing may be due to several factors: aging, medication or noise. Since you presently work in a noisy area, we ask that you begin to wear hearing protection on the job, if'yu do not already do so. The appropriate hearing protection will be provided. The hearing protection is to help insure that no further changes in hearing will occur due to noise. We will be rechecking your hearing in the next few months to determine if your hearing has stabilized. We encourage you, until that time, while working around noise to use hearing protection both on and off the job. If you have any questions regarding this letter, or if you have questions at any time concerning your hearing, please do not hesitate to call the Medical Department. Thank you for participating in Alcoa's Hearing Conservation Program. Very truly yours, LOCATION MEDICAL DEPARTMENT Soc. Sec. No. 001-001-0002 Department No. 002 HQ 001586 INDUSTRIAL HYGIENE RULE IH-004 - HEARING CONSERVATION PROGRAM Revised 1992 January 01 Page 10 APPENDIX D TRAINING PROGRAM OUTLINE I. Description of the Program A. Objective of the Program B. Elements of the Program (-1 ? ^ 1. Identification of Noise Hazards 2. Noise and Personal Exposure Surveys 3. Engineering Controls 4. Hearing Protection 5. Audiometric Testing 6. Employee Education C. OSHA/MSHA Standards and Rockdale Operations' Requirements II. Audio-Visual Presentations: - "Hear Today - Gone Tomorrow" - "Just the Facts" (CORE Chapter 17) - "Hearing Safety" (Tel-A-Train) III. Handouts: - "Just the Facts" - On-the-Job Pamphlet - "Hearing Safety" - Off-the-Job Pamphlet - Hearing Protectors IV. Review: "Do you know the answers?" - CORE Chapter 17 Review HQ 001567 INDUSTRIAL HYGIENE RULES RULE NUMBER: __________IH--005 DATE: REPLACES RULE NUMBER. 1992 Auoust 10 IH-005 OF DATE(S) 92-01-01 RE: HAZARDOUS MATERIALS HANDLING COMMITTEE POLICY OH CONTAINER DISPOSAL Rockdale's container disposal policy is summarized below: Empty Containers Approved for Release to Employees Type Container Material Contained Fiber Drum Fiber Drum Plastic Pail Plastic Pail Open Top Metal Drums Tabular Alumina Activated Alumina Soap Refractory Cement (Penseal 25) Non-toxic or Non-hazardous Alloying Material Supervisors are responsible for insuring that containers to be taken are clean. Their signature on the gate pass attests to the fact that they have inspected and released the containers. It is important that this inspection be thorough in order to avoid incidents which could result in liability claims. Empty Metal Container Disposal Returnable empty metal containers are accumulated at the waste storage pad in the South yard and sold to D.O.T.-approved reclaimer. Non-returnable metal containers are also accumulated at the waste oil storage pad in the South yard for disposal in the Class II landfill. Disposal is accomplished by taking accumulated containers to the landfill at a time when the area is being worked on by the bulldozer. This will facilitate immediate crushing and covering of the containers. Accumulated metal containers, other than those on the approved list, are not to be released for any use inside or outside the plant fence because of potential chemical exposure hazards and because severe explosions and/or subsequent fires may result if welding, cutting, or other hot work is done on containers that may not be entirely free of combustible solids.,, liquids, dusts, and gases. ALCOA HQ 001568 f INDUSTRIAL HYGIENE RULES RULE NUMBER: IH-006 DATE: REPLACES RULE NUMBER: 1992 January 01 1-005 OF OATE(S). 82-07-27 RE; PROCEDURES FOR IM-PLAMT CONTROL OF HAZARDOUS MATERIALS Early identification of hazardous materials is vital if controlled usage is to be accomplished with minimum risk. The use of the Purchasing-Stores function as the primary control and check point seems to be logical and at locations where it has been tested, has proven to be very effective. The early participation of the requisition writer (and those who countersign requisitions) insures that the people who are closest to the in-plant users of the material are aware of the hazards. Control of the procurement of hazardous materials will be accomplished as follows: 1. New items to be purchased enter our system by means of a Purchasing Department Requisition (Form Number SF25) or through an Addition to Stores (Form Number SF225.) Upon receipt of the SF25 or SF225, the known non-hazardous materials will be processed and handled in the usual manner. For all other items, the Purchasing Department Buyer will check to see if an Alcoa Material Safety Data Sheet has been issued. If so, this will be noted on the request form and it will be processed. The resultant order will carry an appropriate note such as: "If any product covered by this purchase order is, or contains, a chemical substance as defined in Title 40, Part 710 of the TOSCA regulations and/or must fulfill shipping and package requirements of Title 49 of Code of Federal Regulations, vendor's acceptance of the order indicates its compliance with all regulations." or, "Supplier is to furnish material safety data sheets (OSHA Form 20) specifying generic and trade name of product, product specification, full hazard information including receiving and storage hazards. Instructions and special equipment needed for handling and instructions for disposal of material and containers in accordance with RCRA regulations." - ALCOA HQ 001569 A INDUSTRIAL HYGIENE RULE IH-006 - PROCEDURES FOR IN-PLANT CONTROL OF HAZARDOUS MATERIALS Revised 1992 January 01 Page 2 Any other requests on which there could be any questions about possible hazards are to be copied and both the copy and the original are to be "red-flagged". The copy will be returned to the request originator along with instruction sheets requesting more information on the material and how it will be used. These sheets are shown as Attachment A. The original request will be promptly processed into an inquiry by Purchasing in the usual manner except: A. Every effort will be made in the inquiry to obtain full hazard information from the supplier. B. No commitment will be made until the requested information from the requisition writer and the vendor has been received and a determination has been made that the material can be handled safely. C. Once the material has been approved and ordered, it will be added to the plant material inventory. 2. Materials currently in use in the plant have been listed and are included, along with descriptive information concerning the hazards, in the Industrial Hygiene Survey. This information is available on request from the Environmental Superintendent. HQ 001570 FROM ATTACHMENT A TO RE: HAZARDOUS MATERIALS RED FLAG REPLY REQUISITION NO. Reply needed by. .or sooner There Is s possibility that the material on your requisition could be defined as a "Hazardous Material". Often this can be classified with more Information from you. Please review the "Hazardous Material Definition" and supply as much of the following information as you can: 1. If your description is by trade name or catalog number, please complete the description In layman and scientific - language. (Include both Generic Description and Proprietary Names) What are the ingredients? 2. Do you foresee any hazard potential? (Fire, corrosive, Irritant, poisonous by Ingestion, inhalation, skin absorption, etc.) 3. Does the product deteriorate when package Is broken? Can or will any of the hazard shown In (tern 2 above occur In the presence of high humidity or rain? Does high or low transport and storage temperature create any hazard potential? Is long storage unadvlsable? 4. Any special protective equipment required for people handling or using the material? Can it be stored near other materials with safety? 5. What are you setting out to accomplish by use of the material? What Is its function and how will it be used? What leas hazardous alternate materials could be acceptable? ' 6. What disposition can be made of material after It has served your purpose? Any ecology problems? Any potential salvage? . Your prompt reply will speed the order release and delivery o! your requisition. HQ 001571 ALCOA HAZARDOUS MATERIAL DEFINITION: GASES, VAPORS, LIQUIDS, SOLIDS OR PARTICULATE HAVING ONE OR MORE OF THE FOLLOWING CHARACTERISTICS' 1. Flammable (lash point, closed cup Below 100*F (37.8 *C) Z Combustible flash point, closed cup Between 100 and 200*F (37.8 and 93.3 *C) 3. Toxic by Inhalation Threshold Limit Value (TLV) Gas or vapor, PPM Particulate, MG/M3 Particulate, MPPCF Below 500 Below 10 Below 30 4. Toxic by Ingestion Single oral dose MG/KG of body weight LD50 for rats Below 500 5. Toxic by absorption Skin contact (dermal) MG/KG of body weight - LD50 for rabbits Below 2000 6. Chronic Toxicity Materials having serious or irreversible chronic health or environmental toxicity . as determined by the corporate Industrial Hygiene and Medical Dept, or Environmental Control Dept 7. Visible Destruction or Alternations to Tissue at Site of Skin Contact . 24*hour test 8. Hazardous Processes In course of normal operations, can produce gases, vapors, or particulate having one or more of the above characteristics. ' 9. Chemical Reactivity Any material that, as a result of foreseeable storage or processing and/or as a result of Interaction with other materials, has the potential of readily detonating or polymerizing with the release of a large amount of . energy, undergoing spontaneous combustion, and/or generating other hazardous materials (gases, vapors or particulates) having one or more of the above characteristics. 10. Radioactive Materials These materials are fully covered by the Nuclear Regulatory Commission (NRC) regulations. All Alcoa locations using radioactive sources have a radiation safety supervisor. (The above Is extracted from Engineering Standard 18.15 Section 2) HQ 001572