Document BRdBBM9jNzwVye17pE6L0yVmX

FILE NAME Oil Industry and American Petroleum Institute API DATE 1961 July DOC API117 DOCUMENT DESCRIPTION The Medical Bulletin Article - Industrial Hygiene Risks of Mechanical Operations in a Petroleum Refinery THE MEDICAL BULLETIN JULY 1961 EDITORS R. Schneider M.D. N. J. Roberts M.D. J. Thorpe M.1 R. Lee M.D M. Daley M.D W. Wakeley Jr M.D. P. Wagner R.N. R. McDiarmid McDiarmid Med Adm Constance Lima Secretary STANDARD OIL COMPANY NEW JERSEY AND AFFILIATED COMPANIES VOLUME 21 NUMBER 2 2 Copyright 1961 Standard Oil Company New Jersey 30 Rockefeller Plaza New York 20 N. Printed in U. A. Bs ; GP Pe oe bodeerpwse, INDUSIF iP INDUSTRIAL HYGIENE ASPECTS OF MECHANICAL OPERATIONS IN A PETROLEUM REFINERY W. MEYER and F. W. CHURCH Esso Research and Engineering Company Exposures to chemicals and physical agents by workmen in the mechanical crafts cover essentially the entire realm of industrial hygiene concern Such problems range from the inhalation of and physical contact with vapors dusts and fumes to excessive heat noise and radiation Mechanical craftsmen may work either in a centralized shop or in Company Company the field In general the severity of exposure is greater with field work than with similar work in the shop Many times field work must be done in confined spaces where the provision of adequate ventilation Company may be difficult Under these conditions for example a welder may have higher exposures than normally occur in shop welding e Divsion In many industries as in petroleum automation and mechanization e have reduced the exposures to process operators Proportionate redue- Engierng tions have not always been made in the mechanical crafts In addition Res arch new processes and materials of construction have tended to increase and At. the already imposing list of hazards As an example in the relatively BAERhe new field of chemicals many solvents catalysts and chemicals Medical Tart are used which were not previously encountered Alloy metals and de Resarch tae protective coatings are more and ntore in use which may produce rt aad quite toxic dusts fumes and gases under heated conditions or when Esso OED abrasive NR The importance and scope of industrial hygiene evaluation and ee engineering control of the environment in which the mechanical a SE craftsman must work is further evidenced by the fact that roughly We 50 of a refinery work force may be employed in the mechanical en trades compared to 25 each for process and other employees we a In the attached listing are summarized some of the more important Ba mechanical operations the potential hazards and suggestions for con- trol methods While basically prepared for shop operations the tA general principles can be translated to other conditions Actual assess- eB Sandi ments of the environmental factors should be made by means of industrial bygiene techniques to determine the extent of controls Se required 256 Or Oa whe ee gf 2 be . BoE Yon 3 ard 5 * eF = Rk 7 = x = x i os = Ere : yo>DSoe:so cf ZaE mY 1 a = = 7 SBa07 ce & rec ms & ~ Se oa a ina = z= on soe a =. Tet Se = eS 2S wo = Poa ee 5 x fond a Bo BaF me SisgZte 2r2ac 7 mcs Soy an 2A ES =~ < 2S. moo os icc FR RY RY .NICAL Medical Research Division Esso Research and Engineering Company INDUSTRIAL HYGIENE COMMENTS ON MECHANICAL OPERATIONS INDUSTRAL This tabulation will not be complete for all refineries as some may have specialized mechanical work not HYGIEN covered here Also in some locations certain mechanical jobs may not be done in the shops or departments shown in this listing This is not important however since this listing is concerned with the job rather ASPECT than where it may be carried out Area Hazardous Items Comments OF BOILERMAKER SHOP Noise Many of the operations in this area produce noise intense . Free Silica see also welding enough to damage hearing of attendant personnel Cold riveting MECHANIL chipping and plate bending are examples of operations which might require reduction of noise level or personnel protection During pipe bending the pouring of sand in and out as well as the sand handling facilities make the air dusty If the sand used has a high free silica content exposures to this dust must be mini- mized OPERATION OPERATION If weiding is done in this shop the potential exposures listed under welding should be included here CARPENTER SHOP Paint Solvents Sanding Dust Noise IN Various solutions and solvents are used for loosening and A removing paint from objects requiring carpentry In most instances the solvents contain aromatic or chlorinated hydrocarbons and PETROLUM either general ventilation or local exhaust should be provided Skin contact with solvents can produce dermatitis Prompt removal of solvent contaminated clothing and the use of gloves and showers reduce the hazard Sanding operations duce considerable dust Often the work piece has been painte with metallic pigments such as lead or REFINY manganese which can ad the air with extremely toxic materiais 257 Local exhaust should be provided for this operation ny ee) FaBs ee rainpyre yas 258 Area Hazardous Items Circular saws bandsaws planers shapers and the like can be noisy particularly when working on hard woods Efforts to isolate and enclose these operations should be considered ELECTRICAL SHOP Solvents i.e. Benzene Carbon Tetrachloride Trichloroethylene Trichloroethylene Many electrical shops use carbon tetrachloride or similar toxic solvents for cleaning electrical equipment These materials may he sprayed or used as a dip Carbon tetrachloride in particular is highly toxic If required for cleaning electrical equipment special arrangements should be provided such as ventilated hoods or booths so that employees do not inhale the vapors In som applications it is possible to substitute methyl chloroform MAC 500 ppm for carbon tetrachloride MAC 25 ppm thereby reducing the hazardous conditions FORGE and BLACKSMITH SHOPS Smoke Fumes Cyanides Radiant Heat Noise THE Most forges have only a canopy hood placed some distance above MEDICAL them The draft caused by the heat of the forge and the stack effect of the hood is generally insufficient to satisfactorily control the smoke and fumes from forging The hood should be mechanically exhausted to assist the natural draft to provide a satisfactory con- trol velocity over the entire free face area between the forge and the hood It may be expeditious to reduce this free face area by partial enclosure BULETIN Case hardening sometimes employs cyanide salts The entire operation where cyanide salts are involved should be under mechanical exhaust This includes preparation of the salts dipping and sprinkling of the salts over the heated piece and workpiece quenching At forges or furnaces shielding should be used to reduce the amount of radiant heat transmitted to the work place This is particularly true for openings of the furnaces through which the hot interior surfaces can be seen such as the door pyrometer ports and so forth Several operations in the area can produce high intensity noise i.e. drop hammers and furnace burners Efforts to isolate and enclose these operations should be made Hazardous Items Comments INSTRUMENT SHOP Mercury Mercury is often spilled when instruments are repaired and tables INDUSTRAL Solvents i.e. Tetrachloride serviced Accumulation of mercury droplets on floors and other working are`s are`s may easily result in excessive amounts of mercury vapor is attansphere of the work area Careful techatanspher HY niques should be followed to avoid spillage of mercury properly . Dov 1 hot interior interior suriages can and so forth Mita et thy be seen such s through whic me as the door pyrometer ports i.e Several operations in the area can produce high intensity noise i.e drop hammers and furnace burners Efforts to isolate and enclose these operations should be made Area Comments INSTRUMENT SHOP Mercury Mercury is often spilled when instruments are repaired and INDUSTRAL Solvents i.e. Benzoi Carbon Tetrachloride serviced Accumulation of mercury droplets on tables floors and other working arers may easily result in excessive amounts of mercury vapor in the atmosphere of the work area Careful tech- TrichloroethylTricehlornoetheylene niques should be followed to avoid spillage of mercury properly designed stands for tearing down and servicing meters help toward HYGIEN this end In addition good housekeeping and immediate cleaning of spilled mercury does much toward eliminating this hazard See attached drawing Suggested Features for Mercury Meter Repair Stand N2-53 ASPECT If solvents are required for cleaning instruments parts exposure to their vapors may occur Some solvents such as benzol or chlorinated solvents like carbon tetrachloride are extremely OF hazardous These solvents should be handled with care and used tRe only in well ventilated areas If routine use of these materials is required special facilities should be installed for the handling ed and application a MECHANIL a INSULATORS Asbestos MACHINE SHOP Metallizing Cadmium Lead Nickel Zinc Noise Chromium Fluorides MECHANICAL OO If the insulators reclaim old insulation by shredding the ARON shredding device or machine should be provided with mechanical TARE exhaust ventilation to prevent the dissemination of asbestos into the breathing zone Pm OPERATIN The spraying of molten metals and alloys on heterogeneous IN RTE metallic objects introduces fumes into the workroom atmosphere A ORL Control of these fumes is necessary and is accomplished through ome local mechanical exhaust ventilation Fumes of lead lead alloys PETROLUM Sma cadmium and beryllium are extremely toxic and complete respir- atory protection must be provided for the operator and other workers in the fume area SUE is, Degreasing Solvents REFINY Occasionally solvents are required for cleaning pieces These solvents should he handled carefully and used only in well ventilated areas If routine use of these materials is required special facilities should be installed for their handling and applica- enr aot oe ce aN te ee Pet Rages . Babbitting Tool Grinding MASONS Hazardous Items Lead Cadmium Arsenic Cobalt Beryllium Free Silica Radiant Heat Comments tion Many satisfaction commercial units are available for this Skin must be avoided Such solvents as benzene tetrachloe have a high order of toxicity and special caution is required Babbitt metal is the name originally given to alloys of tin lead and antimony Newer materials may also contain cadraium and arsenic Health hazards due to melting of babbitts depend upon several factors such as pot size temperature of melt drossing procedure and disposal methods frequency of melt disturbance by ladling and level of housekeeping Good industrial practice requires thermostatic control of temperature careful drossing and disposal of dross in a separate covered receptacle The need for mechanical THE exhaust depends primarily on the frequency of the operation and quantities handled MEDICAL Exhaust ventilation is recommended for large pots used for melting metal on a production basis Grinders for sharpening tungsten tools should have local mechanical exhaust ventilation to prevent the inhalation of cobalt by the men This cobalt dust comes from the cement used to bond the cutting tip to the shank BULETIN The wheels for grinding and sharpening sparking tools should have mechanical exhaust because these tools are made of a beryllium alloy Sometimes such grinding and sharpening equipment is placed inside the tool crib and all operations are restricted to this area High silica content bricks may be cut or ground to special shapes and sizes The brick masons should have a cut saw containing an integral exhaust system to keep the dust away from their breathing zone Furnaces lined with brick must have the lining removed periodically This operation subjects the workers to high concentrations of dust As the work is usually intermittent approved Hazardous itemis Comments INDUSTRAL filter line respirators should be worn while the work is in progress In the event line respirators are impracticable the respirator approved for protection against pneumoconiosis ducing dusts will provide adequate protection HYL Work invetimus exposes the masons to rot Hadt Heat shapes and sizes containing an integral their breathing zone me masons system exhaust exhaust exhaust exhaust system be ent of grand star should have a cut saw ke p to keep the dust away frott periFoudrincaaclelsy lined brick centrations centrations centrations with must have the lining removed This operation subjects the workers to high conhigh is dust usually approved of dust As the work is intermitent intermitent intermittent Area PAINT SHOP SANDBLASTING Hazardous Items Pigments Solvents Thinners Paint Removers Free Silica Naise Conuments line respirators should be worn while the work is in progress In the event line respirators are impracticable the filter respirator approved for protection against pneumoconiosis ducing dusts will provide adequate protection INDUSTRAL Work within furnaces sometimes exposes the masons to high HYGIEN heat loads Since most of this heat is from radiation it cannot be easily controlled Reflective air cooled clothing may help in withstanding the high temperature Often the best that can be done is to limit the length of work time so as to control the duration ASPECT of exposure Paint is applied by either brush or spray gun The hazards of OF the work come from toxic pigments solvents thinners and re- inovers Pigments may contain lead or other materials having toxic MECHANICAL properties Aromatic materials such as benzol toluene and chior- inated materials such as carbon tetrachloride and trichloroethylene MECHANICAL may be employed as solvents or thinners Both benzol and carbon MECHANICAL tetrachloride are popular materials for paint removers Inhalation MECHANICAL MECHANICAL of these materials may take place around painting operations Good MECHANICAL paint removers are also strong skin irritants OPERATION OPERATION OPERATION Paint shops should have well ventilated drying areas 50 that OPERATION the solvent vapors being emitted during the drying process do not OPERATION OPERATION contaminate the general work area An exhaust hood with a turn- OPERATION table mounted in front of it can provide a means of control when IN painting small objects For isolated spray painting personal A protective equipment should be used and any group of painters PETROLEUM should be placed under medical supervision PPEETTRROOLLEEUUMM PETROLEUM PETROLEUM The health hazard of sandblasting is the inhalation of free PETROLEUM PETROLEUM silica dust possibly leading to silicosis after prolonged exposure PETROLEUM Both the sandblaster and his helper are exposed to t type of REFINERY dust while blasting REFINERY REFINERY There are generally two types of sandblasting @ i both of REFINERY REFINERY these require protection for the worker The first is sar lolasting in REFINERY one central location to which the parts are brought to cleaned be cleaned 262 Area 262 TIN SHOP Hazardous Items Hazardous Hazardous Items Comments OTe Coments Commonly this work is done in a of sandblasting is done in field room or cabinet The other type locations since the work is too large to move In this type the structure operator moves over the entire Lead Fluorides Cadmium Zinc Chlorides structures aTrhee dmieftfheroednst oWfhceornterolling exposure to dust in these two situations is usual to sandblasting is done in a room or cabinet it the supply these structures with exhaust ventilation Where operator stands on the outside of a cabinet ventilation may be designed as to preclude the or booth the blasting Helmet However where the wearing of a sand- cabinet he must operator stands inside of the blasting is done wear in an approved blasting helmet Where sand- the open or on process equipment and the like about the only method of is for the operator to protecting the individual THE use an approved sandblasting helmet Dust helper type respirators may be adequate for the The actual exposure to silica dust can be MEDICAL idsusotbvcioouunststhaNteatrhe the nozzle where the blasterevhailmusaetlefdstoannldys biyt the exposure counting of dust in would be extremely high Therefore a to reveal a health such situation is useless as it is not needed hazard On the other hand where it is observed BULETIN dtehsaitraobtlheer workers are being exposed to silica dust it be by an to determine the level individual of exposure This should may be done collecting and trained in the industrial hygiene techniques of counting dust samples Exposed personnel should be placed under close medical supervision 1 Lead The heating of lead solder so that it will bond with other to the flow point usually performed with metallic surfaces when cooled is The temperature of the a hand soldering or tinning pot injurious melt is usually not high enough to produce off of concentrations soldered of lead fumes However during the shake parts finely divided particles of lead dispersed to the general room may he off exposure where large parts atmosphere Control of the shake exhaust ventilation are involved is through mechanical ~ ios Area Hazardous Items Comments INDUSTRAL Fluxes and various cleaning solutions contain chlorides or free hydrogen chloride A hood with mechanical exhaust should be provided in any cleaning area 2 Silver Solder The process of silver soldering sometimes known as hard soldering involves the use of an oxyacetylene HYGIEN city torch to melt the silver soirler in the When borax or horacic acid used presence no health and je te TIN SHOP Load Fluorides Cadmium Zine Chlorides 1 Lead The heating of tin solder to the flow point so that it will bond with other metallic surfaces when cooled is usually performed with a hand soldering or tinning pot The temperature of the melt is usually not high enough to produce injurious concentrations of lead fumes However during the shake off of soldered parts finely divided particles of lead may be dispersed to the general room atmosphere Control of the shake off exposure where large parts are involved is through mechanical exhaust ventilation Area WELDING ani CUTTING Hazardous Items Comments Fluxes and various cleaning solutions contain chlorides or free INDUSTRAL hydrogen chloride A hood with mechanical exhaust should be provided in any cleaning area 2 Silver Solder The process of silver soldering sometimes known as hard soldering involves the use of an oxyacetylene or HYGIEN city torch to melt the silver solder in the presence of a flux When borax or boracic acid is used no health hazard is presented by the flux However some types of work call for the use of a flux containing fluorides These fluorides are hazardous if breathed in appreciable quantity Workers also should be cautioned not to get fluoride flux on the hands ASPECTS Some silver solders contain appreciable quantities of cadmium OF which can be vaporized into the worker's breathing zone Control when required is through mechanical exhaust ventilation Fluxes Fluorides Chlorides Metals Cadmium Manganese Zinc Nickel Other Oxides of nitrogen Ozone Radiation Infra violet X and Gamma If welding operations are conducted in this shop potential exposures similar to the list under welding should be considered MECHANIL There are two classes of welding and electric The gas types are oxyacetylene oxyhydrogen and atomic hydrogen Elec- OPERATIN tric types are metallic arc carbon are and resistance The newer methods such as shielded arc submerged arc and magnetic are and magnetic flux are electric also The hazards incident to the operation are varied in their nature and severity IN The requirements for health protection and ventilation in welding and cutting have been established by the Americam PETROLUM Welding Society on the basis of the three following factors which govern the amount of contamination to which welders may be . exposed 1. Dimensions of space in which welding is done REFINY 2. Number of welders 3. Possible evolution of hazardous fumes and gases according to the metals involved Xe 2 Pas N7pfeme MS ae! teMm hog! EER, Hazardous Items Comments As guide only 2000 CFM welder should be supplied as general ventilation when welding or cutting mild steel in spaces of less than 10,000 cu ft welder or in a room having a ceiling height of less than 11 11. Natural ventilation may be sufficient when these confined S acei acei itations do not exist Fumes from beryllium cadmium lead chrom or mercury are extremely toxic and local exhaust and or suppe air respirators are generally required Where local exhaust is used a freely movable hood intended to be placed by the welder as near as practical to the work should provide sufficient air flow to maintain 100 linear min in the direction of the hood at its remotest distance from the point of welding Eye protection must be provided the density of color of the protective glass being dependent upon the intensity of the radiation THE Flash shields should completely enclose the inert gas welding MEDICAL area to protect the eyes of workers other than welders The bottom of the shields should be a short distance above the floor to help create natural convection currents The newer welding processes produce around ten times the amount of ultraviolet radiation as does ordinary arc welding Protection of onlookers in these cases BULETIN is exceedingly important ray machines and gamma ray sources are used to test welds Film badges and direct reading pocket dosimeters should be worn during radiographic work Short exposure times and the greatest possible distance from the radiation source are the most effective means of reducing exposures INDUSTRAL SHEYOR BIKOTL RSNOUL01T1 ak NOM VD m0 TG ii sy)d CE SMU SKOISK 18297 yo! Yar AVG V3A) S10d FIdTS THY SJINAOD HYGIEN Te n J *y Le * a INDUSTRIAL HYGIENE ASPECTS OF MECHANICAL OPERATION IN A PETROLEUM REFINERY 2 At ae ep ' weanyeae ee Sas s ^' ' 7 29 29 i TOOL we BOARD BOARDBOARD BOARD e s] Jo2-~-+4i TOLJMLERCURMEYMRECRURCYURYMERCURYMERCURY TRAPTRAP TRAP ted | H H |H Vi: PROVIDE CASTERS - eo | BOARD 4 ecerocr f t DIMENSIONS ARE ONLY SUCCESTIONS AND ARE NOT CRITICAL CAN BE CONVENIENTLY MADE FROM SHEET STEEL AND ANGLE NO 1ROK BRASS.LEAD OR COPPER USED i TROUCH SLOPES TO DRAIN AND IS FILLED WITH WATER MOUNTING POSTS ARE SUCH SUCH SIZE SIZE AND HEIGHT TO PLACE METER CONVENIENTLY FOR REPAIRMAN WORKING LEVEL TROUCH TO BE WASHED OUT WITH VARSOL OCCASIONALLY TO REMOVE ACCUMULATED GREASE AND OIL ALL CRACKS AND CREVICES TO BE CLOSED BY WELDING OR PUTTY ALL HORIZONTAL SURFACES TO KEPT TO A KINIKUM