Document 7RKX7KbzKeG7GQMy6gGmo15zB
Shell Oil Company Shell Chemical Company
A DrviSKKi of Sfwll Otl Company
December 14, 1983
Deer Park Manufacturing Complex PO Box 100 Deer Park. Texas 77536
Brown and Root ATTN Bill Briley
Brown and Root Safety
Dear Bill,
Attached are the results of monitoring performed by the Industrial Hygiene Department during the August 1983 Shutdown at the Catalytic Cracking Unit. Included in this report are observations and recommendations for future shutdowns.
WELDING FUME SAMPLING
Welders working in areas with poor ventilation were monitored to assess their exposures to welding fumes. The following table lists the permissible exposure level for each specific fume based on an eight hour time-weighted average sample.
TABLE 1
ALLOWABLE CONCENTRATIONS OF METAL FUMES
Substance
DPMC Guideline (mg/m^)
Total Welding Fume Chromium, Total Nickel, Total Iron (Nuisance Dust)
5.0 0.5 1.0 10.0
DPMC-05171
LAM 008669
PAGE 2
Five of the eighteen samples collected exceeded the allowable concentration for total welding fume. Three of ^these samples also exceeded the permissible exposure level of 10 mg/rn for nuisance dust. All three of these samples were collected on welders working inside the Regenerator. These measurements continue to support the need for respiratory protection on future shutdowns.
VENTILATION The number of air movers used during this shutdown was basically the same as that used during the previous two major shutdowns (September 1980 and December 1982). Measurements were taken with a Davis Rotating Vane Anemometer to determine air.flow inside the Reactor and the Regenerator. One set of measurements were taken with the Copous Blowers driven by steam and a second set taken while the blowers were being driven by air. It v/as found that the Copous Blowers suffer a marked reduction of efficiency when operating under air power. Attachment II is the ventilation summary for the Reactor and Attachment III represents the Regenerator. RESPIRATOR USE The use of respiratory protection by personnel working inside the Reactor and Regenerator did not consistently meet or comply with the conditions for entry specified by permit. Frequently contractor employees were observed without the required dust masks. The available exposure monitoring data continues to highlight the need for protecting against dust exposure during CCU shutdowns. This deficiency should be reviewed by the appropriate level of contractor supervision.
DPMC-05172
LAM 008670
PAGE 3
RECOMMENDATIONS There are three areas that need special attention on future shutdowns. 1. Continue the use of the access houses at open manways. An extra effort
may be required to assure that all hoses and cords are routed through the appropriate side opening so doors may be fully closed. 2. Continue the u-se of dust masks and goggles for entry into the Reactor and Regenerator. Craft supervision should be informed of the requirement and should enforce this.
We encourage you to convey these results to all employees involved with the shutdown. If you have any questions please call me at extension 7102. Your cooperation is greatly appreciated. Sincerely,
P.0. Snyder Sr. Industrial Hygienist Attachments
DPMC-05173
LAM 008671
PERSONNEL MONITORING RESULTS FOR WELDING FUMES
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LAM 008672
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LAM 008673
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DPMC-05176
LAM 008674
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DPMC-05177
LAM 008675
VENTILATION SURVEY ATPi FTTDvv Kt^SUFTt.MEATS
REACTOR - STEAM POWERED COPOUS BLOWERS
See Drawing 1 for location of sample points.
Location
1. 3705 feet per minute (fpm) - electric air mover 20" manway diameter 8078 cubic feet per minute (cfm)
2. 2475 FPM - Copous Blower 20" manway diameter 5397 CFM
3. 3375 FPM - electric air blower 24" manway diameter 10598 CFM
4. 2750 FPM - Copous.Blower 24" manway diameter 8635 CFM
5. 750 FPM 60" manway diameter 14,718 CFM
6. 690 FPM 24" manway 2166 CFM
7. 8000 FPM - air conditioner duct 24" manway diameter 25,120 CFM
8. 300 FPM 30" manway diameter 1472 CFM
9. 175 FPM 54" manway diameter 2782 CFM `
DPMC-05178
LAM 008676
REACTOR - AIR CHANGES PER HOUR
Location
(-) Net Air Flow,Out
1. -8078
2. -5397
3. -10598 4. -8635
5.
6.
87..
9.
TOTAL AIR FLOW
-32708
Air Changes Per Hour = N
N = 60(R)/Q
N = 60(46,258) 32,000
N = 86
(+) Net Air Flow, In
14718 2166
25120 1472 2782
46258
DBS12 12-2-83
DPMC-05179
LAM 008677
PEGEKEPATQR WITH STEAM ON
See Drawing 2 For Location of Sample Points
Location No.
1. 602 (FPM) Copous Blower 30" manway diameter 2953 (CFM)
2. 1488 FPM - electric air mover 24" manway diameter 4672 CFM
3. 1492 FPM - electric air mover 20" manway diameter 3253 CFM
4. 2074 FPM - Copous Blower 24" manway diameter 6512 CFM
5. 3480 FPM - Copous Blower 24" manway diameter 10,972 CFM
6. 754 FPM 84" manway diameter 29,003 CFM
7. 8100 FPM - air conditioner duct 24" manway diameter 25,434 CFM
8a. 4776 FPM - steam adductor 24" manway diameter 14,997 CFM
8b. 540 FPM 14" manway diameter 577 CFM
9. 200 FPM 20" manway diameter 436 CFM
10. 3744 FPM - electric air mover 30" manway diameter 18,369 CFM
DPMC-05180
LAM 008678
REGENERATOR - STEAM OFF, AIR POWER Location 1. Not available 2. 1272 FPK - electric air mover
24" manway diameter 3994 CFM 3. 1752 FPM - electric air mover 20" diameter 3820 CFM 4. 2608 FPM - Copous Blower 24" manway diameter 8189 CFM 5. 1020 FPM - Copous Blower 24" manway diameter 3202 CFM 6. 350 FPM 84" manway diameter 13,462 CFM 7. 560 FPM 24" manway diameter 1758 CFM 8. Not available 9. 245 FPM 20" manway diameter 534 CFM 10. Not available
DPMC-05181
LAM 008679
REGENERATOR - AIR CHANGES PER HOUR
A. STEAM ON
Location
(-) Net Air Flow,Out
1. -2953
2. -4672
3. -3253 4. -6512
.5. -10972
6 7. 8a. -14997 8b.
.9.
10 -10369
TOTAL AIR FLOW
-61728
Air Changes Per Hour = N R = Net Air Flow Q = Vessel Volume
N = 60(R)/Q
. N = 60(55,450) 83,000
N = 40
B. STREAM OFF, AIR SUPPLY TO COPOUS BLOWERS
Location
(-) Net Air Flow,Out
1.
2. 3. 4. 5. 6. 7. 8. 9. 10.
TOTAL AIR FLOW
Air Changes Per Hour = N
N/A -3994 -3820 -8189 -3202
N/A
N/A
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N = 60(R)/Q
N = 60(15,754) &3,uTiU
11. U ~
(+) Net Air Flow,In
29003 25434
577. 436 55450
(+) Net Air FIow,In
13462 1758 534
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DPMC-05182
LAM 008680