Document pyJem2N5Lje26DBkR1EExoKa
5^-32-MC (REV. 4-79)
Shell Oil Company Shell Chemical Company
Interoffice Memorandum DECEMBER 13, 1983
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FROM: TO: SUBJECT:
SR. INDUSTRIAL HYGIENE TECHNICIAN DEER PARK MANUFACTURING COMPLEX
PROCESS MANAGER - CATALYTIC CRACKING UNIT DEER PARK MANUFACTURING COMPLEX
INDUSTRIAL HYGIENE MONITORING DURING 1983 CCU SHUTDOWN
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.
CATALYST HANDLING
Although not sampled, the control of catalyst dust during the unloading of the Reactor and Regenerator was much improved over the December 1982 shutdown. The contractor handling this aspect of the shutdown did an excellent job of controlling the catalyst dust. This improved dust containment, along with the use of goggles around the Reactor and Regenerator structure during unloading of catalyst, reduced the number of minor eye irritations associated with airborne dust from 25 minor eye irritations in December to nine during this shutdown.
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/m3)
Total Welding Fume Chromium, Total Nickel, Total Iron (Nuisance Dust)
5.0 0.5 1.0 10.0
LAM 006150
DPMC-18031
PROCESS MANAGER - CCU
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/ni 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 was 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.
LAM 006151
DPMC-18032
PROCESS MANAGER - CCU
PAGE 3
RECOMMENDATIONS There are three areas that need special attention on future shutdowns.
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.
Attachments
cc: H.F. Ely R.R. Erickson R.L. Hartman H.L. Lee P.J. Snyder
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LAM 006152
DPMC-18033
PERSONNEL MONITORING RESULTS FOR WELDING FUMES
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^006556 DPMC-18037
VENTILATION SURVEY AIR FLOW"'MEASUREMENTS
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
LAM 006157
DPMC-18038
REACTOR - AIR CHANGES PER HOUR
Location
(-) Net Air Flow,Out
1. -8078
.2 -5397
3. -10598 4. -8635
5.
6.
7.
8.
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
LAM 006158
DPMC-18039
REGENERATOR 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
LAM 006159
DPMC-18040
REGENERATOR - STEAM OFF, AIR POWER Location 1. Not available 2. 1272 FPM - 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
LAM 006160
DPMC-1B041
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 COPOUS BLOWERS
Location
(-) Net Air Flow,Out
.1. N/A
2 -3994
3. -3820
4. -8189
.5. -3202
6 7.
8. N/A
9.
10. N/A
TOTAL AIR FLOW
-19205
Air Changes Per Hour = N
N = 6 0 (R) / Q
N = 60(15,754 83,000
N = 11
(+) Net Air Flow,In
29003 25434
577 436 55450
(+) Net Air Flow,In
13462 1758 534
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LAM 006161
DPMC-18042
lAM\6^9
D PM C 18030.1
