Document nR2gLeXxzXK9k1JnOyda3kqw

Corporate Office O'Hare Corporate Center 1300 Higgms Road Suite 301 Park Ridge. IL 60068-57T2 S47 ' 693-4700 FAX S47 . 692-3137 *" Regional Office Chicago ' FIBER RELEASE STUDY MARITIME FITTINGS MAKING GASKETS WITH A BALL PEEN HAMMER December 18,1996 BAI Project #1418A-4602 TABLE pF CQN(IN.T? C M C M C M C M C V IC O C O C O C O T f i n U1 U1 If) (O N A,Q. EXECUTIVE SUMMARY.................................................................................................. Objectives ............................................................................................................. Background ........................................................................................................... - Sample Results ................................................................................................... 1 i 1 i METHODOLOGY.................................................... PCM Sampling Procedure......................... Personal Samples ...................................... Average Room Air Samples ..................... Background Air Samples for TEM Analysis Background Air Samples for PCM Analysis Light Microscopy Analysis ......................... Electron Microscopy Analysis ................... Statistical Comparisons............................. Laboratory Accreditation ........................... DISCUSSION OF FINDINGS ............................... Isolation Test Chamber............................. Background Sampling Results................... Selection of Fittings.................................... Gasket Making Test Method ..................... Sampling Results During Test................... CONCLUSIONS................................................................................................................. 9 APPENDICES A Compilation Spreadsheets and Graphs - TESTING RESULTS B - Compilation Spreadsheets and Graphs - PRE-TEST BACKGROUND RESULTS C - PCM Laboratory Reports D - TEM Laboratory Reports E Original Photographs - FIBER RELEASE STUDY MARITIME FITTINGS MAKING GASKETS WITH A BALL PEEN HAMMER Objectives EXECUTIVE SUMMARY The purpose of the study was to determine the concentration of fibers in the air while gaskets were made from stock material with a ball peen hammer. Background The study was performed using intact flanges from maritime fittings. The fittings and flanges had been in service many years and were obtained from three (3) decommissioned US war ships. The study was conducted in an isolation chamber to eliminate outside influences. The study was conducted at the rate of one (1) gasket per hour over an 8-hour period. The study was conducted on December 16, 1996 by Mr. Fred Boelter. This report presents the results of the study described herein. Sample Results All samples measured concentrations of fibers in air well below the U.S. Department of Labor Occupational Safety and Health Administration (USDOL-OSHA) 8-hour Time- Weighted Average (TWA) Permissible Exposure Limit (PEL) of 0.1 fibers per cubic centimeter (f/cc). Sample results are presented in the accompanying tables. . Fiber Release Study - Maritime Fittings/Making Gaskets with a Ball Peen Hammer December 18, 1996 Page 2 METHODOLOGY PCM Sampling fpwflro Samples were collected and analyzed following NIOSH Method 7400. Air was drawn through a 25mm, conductive cowl cassette with a 0.8 micron mixed cellulose ester (MCE) fiitetfor collecting airborne particulate. The cassette was connected to a dedicated Giiian servo-drive pump. The pump was used to maintain a flow rate of two (2) liters per minute (Ipm) for both personal and area room air samples. A Brooks rotameter was used to calibrate the pumps prior to and post sample collection. The rotameter was calibrated against a primary standard. ' The samples were sealed, labeled and shipped to the laboratory for analysis. Samples were signed by BEC, placed in a UPS shipping envelope, sealed, tracked by UPS. and arrived at the laboratory by next day air. Eeosgoal. Samples Personal samples were collected by attaching the cassette in the breathing zone of the individual performing the work for the duration of the test. The sampling pump was worn on the individual's belt. ' Average Room Air Samples . . .~ * The isolation chamber was subdivided into 3,600 one cubic foot (1ft3) modules. For purposes of identification, each module was assigned a discrete, consecutive number. To determine the average room air concentration, eight (8) of the modules were selected using a random number generator. A sample cassette was located in the center of the respective module for the duration of the test. Background Air_Sambles for TEM Analysis _ Prior to conducting the test, the room was sampled to verify cleanliness. Five (5) samples were analyzed by transmission electron microscopy (TEM) following AHERA Protocol. Just prior to collecting the samples, a "leaf blower" was utilized to aggressively disturb the isolation chamber's interior surfaces. Air was drawn through a 25mm. conductive cowl cassette with a 0.8 micron mixed cellulose ester (MCE) filter for collecting airborne fibers. The cassette was connected to a dedicated Gast high volume pump. The pump was used to maintain a flow rate of 10 liters per minute (Ipm). A BGI rotameter was used to calibrate the pumps-prior to and post sample collection. The rotameter was calibrated against a primary standard. * m Fiber Release Study * Maritime Fittings/Making Gaskets with a Ball Peen Hammer December 18, 1996 Page 3 The samples were sealed, labeled and shipped to the laboratory for analysis. Samples were signed by BEC, placed in a UPS shipping envelope, sealed, tracked by UPS, and arrived at the laboratory by next day air. Background Air Samples for PCM Analysis Simultaneous with collecting the five (5) samples for analysis by AHERA Protocol, three (3) additional air samples were collected in accordance with NIOSH 7400 for PCM analysis "on-site" in the BEC office. The same analytical procedures were followed in the BEC office as were used in the laboratory. An Olympus Model CH-2 phase contrast microscope was used for the BEC analyses. Lia*ilMi[gsaaBy,.Analysis Samples were analyzed in accordance with NIOSH Method 7400. Total fiber counts were determined by phase contrast microscopy (PCM) in accordance with the NIOSH Manual of Analytical Methods, Fourth Edition, dated 8/15/94, A Rules. Values for PCM analysis are provided in the Appendix A and Appendix B spreadsheets. Only fibers longer than 5 microns which have a length to width ratio equal to or greater than 3:1 are counted. PCM analysis counts all fibers meeting the specified dimensions. The analysis is not specific for asbestos but is the method specified to be used in the OSHA regulations. The PCM laboratory reports are presented in Appendix C. Electron Microscopy Analysis AHERA Protocol transmission electron microscopy (TEM) analysis was performed on all background samples to verify the cleanliness of the isolation chamber prior to beginning the test. The sample analysis was performed as described in the Federal Register Vol. 52, No. 210, the Asbestos Hazard Emergency Response Act (AHERA Protocol). Small squares were cut from each filter, processed appropriately, placed onto 200 mesh copper screens (grids) and transferred to a modified Jaffe Wick Washer containing acetone solvent. After the appropriate processing time, the grids were examined with a JEOL 1200EX or 100CX TEM. Grid openings from each sample were scanned at 20,000 X. When fibers or structures of various shapes were encountered, they were assessed for morphological characteristics and crystalline structure with selected area electron diffraction (SAED). The TEM laboratory reports are presented in Appendix D. Statistical Comparisons _ -- Data was formatted in spreadsheets for analysis. Statistical functions were performed including maximum, average, minimum, standard deviation, and variance. Fiber Release Study - Maritime Fittings/Making Gaskets with a Ball Peen Hammer December 18, 1996 Page 4 The spreadsheets in Appendices A and B present the data and summarize the statistical analyses performed. Laboratory. Accreditation The camples were shipped to and analyzed by R. J. Lee Group, Inc. in their Monroeville, Pennsylvania laboratory. R. J. Lee is accredited forTEM analysis by the National Institute of Standards and Technology (NIST) under the National Voluntary Laboratory Accreditation Program (NVLAP) as Lab #101208. R. J. Lee is also accredited for PCM analysis by the American Industrial Hygiene Association (AIHA) as Lab #8204. Fiber Release Study Maritime Fittings/Making Gaskets with a Ball Peen Hammer December 18, 1996 Page 5 - DISCUSSION OF FINDINGS Isplatigh Test-Chamber Testing was perfonned in the Boelter Environmental Consultants' (BEC's) Isolation Test Chamber, The chamber is 20 feet wide by 20 feet deep and is 9 feet in height. The chamber was constructed of 6 mil polyethylene sheeting to physically separate the activity being tested from outside of the chamber influences. The chamber is shown in Figure 1. The chamber was a static environment. FIGURE ^ - BEC Isolation Test Chamber During the test, there was no air movement into the chamber and there was no air movement out of the chamber. During cleaning, the room was ventilated with HEPA filtered air. Entry into the chamber was only through an access airlock. Background Sampling Results Prior to conducting any tests, the isolation chamber was systematically cleaned. Following the cleaning, a series of background samples were analyzed from five (5) area sampling locations in accordance with AHERA protocol. Background samples were collected under "aggressive" conditions with analysis by TEM in accordance with AHERA Protocol. ' Results of the Pre-Test Background sampling are shown in the following table: STATISTICAL FUNCTION Aggressive Air TEM (s/mm1) Background MAXIMUM AVERAGE MINIMUM STAND. DEV. VARIANCE COUNT 8.4 8.4 84 0.0 0.0 5 The levels met the AHERA Clearance Criteria of an average of less than seventy structures per millimeter squared (<70 s/mm2) for the 5 samples and the room was considered clean. Results are shown in the spreadsheet presented in Appendix B. Selection of Fittings ~ Seven (7) fittings with a total of eight (8) flanges were selected for making gaskets with a ball peen hammer. Fittings which were selected for the test were as shown in the following table: Fiber Release Study Maritime Fittings/Making Gaskets with a Ball Peen Hammer December 18, 1996 Page 6 HOUR 1 2 3 4 5 6 7 8 FITTING / FLANGE NUMBER 42A 42B 53A 58A 57A 55A 56A 48C TABLE 1 - FITTINGS SELECTED FLANGE DIAMETER (in.) GASKET OUTSIDE DIAMETER (in.) GASKET INSIDE DIAMETER (in.) 99 4 1/8 9 9 3 15/16 7 1/4 7 1.4 4 6 t<8 6 i/8 2 13/16 6 1'4 6 1/4 2 13/16 3 7/8 3 7/8 7/8 6 1/16 6 1/16 2 3/4 77 4 GASKET BOLT HOLE QUANTITY 8 8 '8 6 6 4 6 8 All fittings were obtained from three (3) decommissioned US war ships.1 All fittings had intact gaskets and flanges and were carefully cleaned prior to being used in the test.2 Gasket Making Test Method A work bench and hoist was placed in the center of the test chamber. The eight (8) fittings selected for the test (See Table I) were all placed in the isolation chamber. Personal and average room air samplers were started prior to beginning the testing. The samplers were stopped after completion of the testing. Testing started at about 8:00am and was concluded at about 5:00pm ("test cycle"). There was about a one hour break starting at about 12 noon. During the testing, no one left or entered the isolation chamber. Each hour during the test cycle, one of the eight fittings was positioned in the center of the room on the work bench ("cycle event"). A typical setup for an event cycle is shown in Photo 1. PHOTO 1 Test setup for making of gaskets. Fitting placed on bench. ' The three (3) decommissioned US war ships were the USS Davis, USS Ricketts or USS King. - " " 2 The fittings were carefully blasted with glass beads to remove surface corrosion, rust, paint, insulation, etc. The gaskets were left intact. A light coat of clear lacquer was spray applied to the fitting after cleaning to prevent rusting. The edge of the flange was masked off dunng spraying to protect the gasket. If not removed, the surface corrosion, rust, paint, and insulation would have interfered with the analysis. The flanges used for gasket making had the onginal gaskets removed in prior tests. The flanges were cleaned pnor to using them as a base for making gaskets. Fiber Release Study - Maritime Fittings/Making Gaskets with a Ball Peen Hammer December 18, 1996 Page 7 Each of the eight cycle events were essentially the same. During the hourly cycle event, similar procedures were followed as described in Table II: STEP 1 2 3 4 5 6 7 TABLE II - TYPICAL HOURLY CYCLE EVENT ACTIVITY Place fitting on work Bencn . Cutting of stock gasket material Separate flange Shaping of gasket material Shaping of gasket material at bolt holes Completed gasket Tighten bolts to 60 tt. lb. PHOTO 1 2 3 .4 5 6 7 Thumbnail photographs depicting the various steps described in Table II follow below. Full size photographs are presented in Appendix E. ' PHOTO 5 - 'Facing* the flange. PHOTO 6 - Completed gasket. Fitting #42B is shown. Fitting #55A is shown. Sampling Results During Test Results of 8-Hour Time-Weighted Average Permissible Exposure Limit sampling are: STATISTICAL FUNCTION MAXIMUM AVERAGE MINIMUM STAND DEV VARIANCE COUNT PCM Anitysit by NIOSH 7400 (Totil l/ce) Personal Simples-' - Average Room Air 0.029 0 026 0.022 0 003 0 000 2 0.025 0.021 0.017 0.003 0.000 8 V Fiber Release Study * Maritime Fittings/Making Gaskets with a Ball Peen Hammer December 18, 1996 Page 8 All sample results show the concentrations to be well below the current OSHA Permissible Exposure Limit of 0.1 f/cc as sampled over an 8-hour time-weighted average period of time. Refer also to Figure 2 for a graphical presentation of the air sample results. Sample Number | | Random Area ' j| Personal 8 hr-TWA Figure 2 - Graphical presentation of the air sample results. The Appendix A spreadsheets and charts present and depict the results of the testing in detail. Fiber Release Study Maritime Fittings/Making Gaskets with a Ball Peen Hammer December 18, 1996 Page 9 CONCLUSIONS Gaskets were made at the rate of one (1) per hour. Eight (8) room air samples and two (2) personal samples were collected during the processing. All sample results show the airborne concentrations of fibers to be well below the current 0HA Permissible Exposure Limit of 0.1 f/cc as sampled over an 8-hour time-weighted average period of time. Respectfully submitted, '' BOELTER ENVIRONMENTAL CONSULTANTS Frederick W. Boetter, CIH, PE, DEE, QEP Reviewed by, /n Gary N. Crawford, CIH w Enclosures F:\APPS\WPS\EXPERT.VY\1418XXXXU 607.BEPORTSVmM6W.MBP m APPENDIX A Compilation Spreadsheets and Graphs TESTING RESULTS -- rN -- OOOOOOOO oooooooo <AN <<NN oe oo m No N~ r> oO O ooooo 0000000606 UJ UJ iiiliill' I <N M a> S NNNNNNNWOONN ssrNtrNtfNifNoNnNowNNoOO sf! 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P O 55 tZ 5 -j UWJ <^N z5E <O E 09 CO CD CO CO air Tl --w 00 CD 09 00 ^ ^ ^ tf> 00 flD 09 O O PRE-ACTIVITY BACKGROUND TESTING RESULTS Codec tndustries/Garlock Packing BAl Project #1418A-4600 sssss n n n nn oooo n n n n n ai : s1 I s: UJ ll CO UJ zs fuz*j ^ ucoj 5co Z uuj yy <UJ <UJ<UJ<UJ<UJ.52< 3<Z < < < < < CD CD ^ cn n v in to s CD CD CD fX) CD CD tp <p (p (0p5 (p O6tt> O04) O60) O68)O6o>Q6vO6C3 (N CN (\ CN fs f\ {N T" 8SS 'laiilz g2|25o 5 < 5 co > O (WOd) =// 05 00 N- <D 1/5 CO CM O b b o' o' o o o /< </ SI O | CM Ui 4? A IS \' V ^^ S3 t Z%c5 v8 2 S ^ S' > U bj ^ Siuj Ol g rsu3 BACKGROUND TESTS - Dec 12,1996 BAI Project 1418A-4600 --tt Ui H ,m Mj :1 %VJ JS*t rs. ,| V il S6 : : : r Sf SI TO V) N UJ (0 NUi N. 5 /> _X'_ O O . ooo oo o oo o oo ooo ooo sT to in Tf" CO CN (vy3HV-^3l)2Luai/s *S ?fe* APPENDIX C PCM Laboratory Reports QC e00 s 6 o c o' c o SS -88 o ?S5S S S3 o tili-BS- ftu5 s Sg *0 *w < T5 - " s P 2 S Si S . s eiooooooo . e r g Sf .ji ^^ *fGn + s SSSig'v'vSS 2 88888881118 n O V in V*n ^ tCnr r**r v> t* n MVT> rV4> * ^ W isiiiiiiiiii^ o--oo 000000000000000000 .ddddddddoodd 2 : J Jg l p^i _ 'i k2 x 0 f--> _ k! x 0 m _ k! S _ k!k2k2k!k2k!k2'k: X 0p- " 0XX0 O I0 X0 0x s0 N n V _ o _ o mo\0<o--*or>~^> ovmcr>-- vmcr"--) ofr----r>> * r-R <m*N> r*i r*> ts t> Is 0.0. XI vx2O ir> as-- 00< ~ fca. Is J2 " 8=5 > <n o 10 Jw l= %. I'gUa! ^c -ae li * |oc f5fi Iig <J JB5 g-ga-s-s 11 S s | ^ * . u e Cu a * 5 O vv 5. "f ee a: V appendix d TEM Laboratory Roports Test Report T o ta l 'Asbestos S tru ctu re C oncentration T E M AI1ERA Analysis Project ATII612933 16.8 V' >C sp >0 <I 5= 7e3 N (N N (N < ir, in in in ieo g 8 gS8 ? ? ?? QO 00 d Vv 00 d V R8 .> 55 8-8 tsCu> ^ o T5 'B X B o oo u vO -> etr> ton 8 8 -8 8 o d oo '00 d S1 - 4 " .1 c. V e 1< o J* e c u 1 ig J? 73 . <co \D O' A o >c VOT'l o SC Os |A vO Os tn A sO Os V> o $z z< e doo d "e S as 88 811 ionc moo mesc r*v ri p*> u. . ' li ^i O r J: . a c: A A A w ^ o> d * O' g.|j 'U-^i-U.^.U.fr- 'WsoC' Jz.I ^ :hs -S*cC. ^;O' #ir**t-, z--: xrN* a f** ~ > zc. oc oc oc oc oc ee K *// 5 x ae x ae x x 1v<l- P2 ll \i - is a viid>#( v 2p sr- ONs t^. o fn mcm cm r? cm c^ 2 EH si 4ee&ep 73 s(0 3 < Vw *s 5" ^| <o-- ei> -I y 5s s -- orr . ir> ~ os: -- 7 ?< & jr?$ Cl. a. Sja ^I = g* fl c i 2H * e r= 8 S. n 3 -O c3 . V3 5c c' E^ uf UU- 3 gy rjsto -.is Ay y S - J~3 <,-ft=>y i| 5s c; --.> ce ^< s5 s >Z ir=f I^ *c a C^ y= =ryz 5S 4 -wCs ` ~= ^ss~ = *r. w= * 2 e. s rS c &> as 2: APPENDIX E Original Photographs -Photo 1Test setup for making a gasket. Fitting is shown on the work bench. -Photo 2Cuttmg gasket material. : coc'e: pM.nGT0 9Pt m * ** -Photo 3Separated flange. Fitting #53 is shown. Photo 4Shapmg of gasket. Fitting #5?A is shown. -Photo 5Factng" the flange. Fitting S42B is shown. ** Photo 7Tighten bolts. Fitting 56 is shown. .* ZZl'zZ Pi