Document xdzVv89R9050pmR60q3pKn3X1

1979 May 21 RE: MASSENA OPERATIONS AUDIT INTRODUCTION Massena Operations includes both smelting and fabricating facilities. The smelting operation consists oft 1) Carbon plant 2) One P-225 potline 3) Two P-75 potlines, with associated pot repairs and __ maintenance activities The fabricating division has facilities for producing: 1) Wire, rod and bar of various sizes 2) Extrusions 3) Bare conductor cable Massena Operations has about 2300 employees, of which about 1500 are hourly. The hourly workers are represented by the Aluminum Workers International Union. Mr. R. K. Morrow, Safety Manager of Massena Operations, has the overall responsibility for Industrial Hygiene. Mr. Gerald D. Hicks, the Laboratory Supervisor, is the Works Industrial Hygienist. He is a chemist with many years of experience, and has acquired additional training to enable him to perform Industrial Hygiene activities. He has completed the NIOSH 550 Course, Industrial Hygiene Measurements, and has had on-the-job training at Warrick prior to his transfer to Massena. Those having Industrial Hygiene and related responsibilities are shown on the abbreviated Organization Chart shown bel&W: OPERATIONS MANAGER HcqCr lAnci J. Reid Clark _________I____________ Q.A. Manager J. R. Feely Chem. Lab. Supervisor G. D. Hicks 1----------- H Safety Manager 1 Medical Director Utujflc. Ous o l-H: Rr K. Morrow M. J. Elder, M.D. . a . 1------------------1 Safety & Security to ' supervisor 1 e Laboratory Staff ABCH 18620 ALCOA MEMORANDUM 1979 May 21 Page 2 PRESENT INDUSTRIAL HYGIENE CAPABILITIES The Laboratory has on-site capabilities to perform a variety of analyses, including gravimetric dust determinations, fluoride analyses, and metal determinations.- Samples for the analysis of Coal Tar Pitch Volatiles, asbestos, and silica are sent to EHL. Industrial Hygiene equipment maintenance, and calibration are performed by three chemists and a technician of the Laboratory staff. The Laboratory staff has received on-the-job training in Industrial Hygiene sampling and analysis, and in making noise measurements. A list of Industrial Hygiene sampling instrumentation available for assessing employee exposures is shown on Attachments^) * y PRESENT INDUSTRIAL HYGIENE ACTIVITIES Industrial Hygiene activities are presently being conducted at Massena Operations on an "as needed" basis; typically, at the request of Plant Supervisors or by Safety or Laboratory personnel *O / as a result of potential hazards being observed in production areas. Although many of the exposures of concern have been checked from time to time, there has not been a procedure for routinely monitoring, exposures, except for urinary fluorides in the potroom area. After the Industrial Hygiene responsibility was assigned to Ron Morrow, a meeting was held to formulate plans for a comprehensive Industrial Hygiene program. From this meeting, it was agreed that Gerald Hicks would make assignment changes in the Laboratory to provide more time for his group to become involved in hygiene activities. All Purchasing Department requisitions will continue to be reviewed by Gerald Hicks for hazardous materials, providing information of where materials are to be used and the need for surveillance. A tentative schedule listing the potential problem areas in the plant has been prepared and is to be used as a guide for Industrial Hygiene sampling. There are also plans to update the materials listed in the 1958 Industrial Hygiene Manual, and to include in it safe handling procedures and other necessary information. In addition, there are plans for setting up a record retention system which will interface with the local Medical Department. In May of 1978, the Massena Operations Industrial Hygiene Committee was reactivated, with representation from areas throughout the plant The members of the Committee, their affiliation, and their Committee duties are shown in the appended memorandum, R. K. Morrow, dated 1978 May 04. 4 r. ARCH 18621 MEMORANDUM 1979 May 21 Page 3 f r ^ 9 '/ <v, > % nr. EVALUATION OF PRESENT INDUSTRIAL HYGIENE PROGRAM The rudiments of an Industrial Hygiene program are present at Massena Operations. The preparation of a list of potential problem areas, updating of the list of process materials, and the continued review of all Purchase Requisitions will provide Massena with a ! reasonably good handle on the location of potential sources of ' employee exposures. rOrMi ~ V The main shortcomings in the present program are the lack of adequate training for^ield personnel, and the lack of^periodic surveillance of the work areas and documentation of full-shift personal exposures. Additional man-hours are required to allow inspections of the various departments and follow-up sampling^. Some of the areas in need of attention are shown in Attachment/Ir) with a comprehensive listing in Attachment /III.) When one considers the 30-40% time spent by Gerald Hicks ancTnis staff, and the appreciable amount of needed work not now being done, there is justification for a full-time professional Industrial Hygienist being employed at Massena. SUMMARY OF RECOMMENDATIONS Review the Quailficationls of personnel performing Industrial Hygiene sampling and~~analysis activities. _________________________ It is understood that Sue Murray, Lab Chemist, is scheduled to attend an AIHA Training Course in Industrial Hygiene. Training and education in various Industrial Hygiene disciplines should be encouraged for those engaged in hygiene activities. - Employment of a full-time professional Industrial Hygienist should be considered.__________________________________________________________ Along with the continued support from the Laboratory and Safety group, a comprehensive Industrial Hygiene program can thus be provided. V - The Industrial Hygiene Committee should schedule SnonUily----meetings._____________________________________________________________J These meetings can be used as a very effective tool in accomplishing the goals of an overall Industrial Hygiene program. - Monthly walk-through surveys should be performed, noting areas where personal samples should be taken and analyzed for occupational exposures. , 0--- Stslj i'-X/ - Every effort should be made to conduct the sampling needs indicated in Massena*s prepared Sampling Guide. - It is recommended that two\additional low f^ow rate pumps and two additional MSA Model G Pump^_be purchased to increase the efficiency of sampling procedures. Jji . fp-1 ids IfJ ARCH 18622 MEMORANDUM 1979 May 21 Page 4 SUMMARY OF RECOMMENDATIONS (Cont.) - A routine procedure for periodic assessment of the effectiveness of ventilation systems in the plant should be established. /eds Attachments Af>CH 18623 'wcmBWE ATTACHMENT I 1. Sampling Pumps Quantity Make/Model MSA Model G SKC Model 222-3S1 Pulse Pump, Environmental Measurements, Inc. 3 1 1 2. Respirable Dust Samplers Type MSA 10mm nylon 3 3. Impingers and Bubblers Type Standard Impingers Standard Impingers as Bubblers Midget Impingers Fritted Glass Bubblers 30 10 9 6 4. Noise Measurement Equipment Type GR 1933 Octave Band Analyzer GR 1562-A Calibrator GR 1558-BP Octave Band Analyzer *duPont D-100 Dosimeter (90 dBA cutoff) 1 1 1 2 *In process of trading the two D-lOOs for five D-376 with 85-90 dBA cutoff. 5. Detector Tubes and Pumps Drager and MSA Pumps with an assortment of detector tubes. 6. Direct Reading Instruments Type Ecolyzer Ecolyzer MSA Combustible Gas MSA Combustible Gas 0/2 Edmont Oxygen MSA Nitrogen Dioxide Unit (Old - Not used) Model 2100 2900 40 250 -- Contaminant CO, 0-100 ppm CO, 0-250 ppm 0-2500 ppm Combustibles Combustibles and 0 % 2 ARCH 18624 ATTACHMENT I 7. High Volume Samplers Gelman Model 1600-3-1 8. Ventilation and Heat Stress Equipment Rotating Vane Anemometer Anemothern Smoke Tubes Various Pitot Tubes and Manometers 1 Equipped Heat Stress Stand Bendix Psychron 9. Analytical Balance Mettler H-51, 5 place Page 2 Quantity # ## f. ARCH 18625 (***&* :rv4. - ATTACHMENT II AUDIOMETRY The Medical Department is equipped with an audiometer and audiometric booth. The four nurses who perform audiometric tests have been certified within the last four years at Environmental Hearing and Vision Consultants, Syracuse, New York, with one recertified by HCNC recently. Audiometric testing is performed as part of pre-employment physicals and on all production employees at the time of their periodic physicals (approximately 3 years). Salaried personnel over 40 years ! of age receive annual physicals, including audiometric tests. /'HCNC ^ made their initial visit to Massena on 1978 June 05-06 and has submitted recommendations on the hearing conservation program. NOISE Noise exposures are one of the most frequently encountered problems throughout the works, especially in the fabricating areas. A plantwide noise survey was performed by short-term help. Following the survey, discussions with Engineering people were conducted regarding each of the problem areas to develop solutions.'iVfter completion of an Engineering project, noise measurements are made to determine the effectiveness of the noise controls. Plans for an annual noise survey of the plant are being developed and will be followed by dosimeter studies in borderline noise areas. ca_/j y CHLORINATED HYDROCARBONS Vapor degreasers using 1,1,1-trichloroethane (methyl chloroform) and trichloroethylene as solvents are found throughout the plant. Testing on the degreasers has been done in the past using detector tubes; however, because of the recent attention given to the potential health / ARCH 18626 ATTACHMENT II Page 2 CHLORINATED HYDROCARBONS (Cont.) hazards associated with the use of chlorinated hydrocarbons, it is 7,/ ,,vm*l~. ii important that sufficient personal sampling be conducted at the vapor /<Y j !j degreasers to document the time-weighted average (TWA) exposures of %K *'( I the operators. It is recommended that sampling be conducted twice per *' \ year: once in the summer when the buildings are open; and in the winter with the buildings closed. ASBESTOS Potential exposures to asbestos fibers exist at the following locations in the Ingot Plant: 1) Mold assembly room 2) Casting and soaking pits 3) Ingot lathing area Marinite headers are pre-cut by an outside concern, minimizing dust exposure; however, dust is produced during hand-finishing and assembly operations in the mold assembly room. Exposure to asbestos fibers exists during the hand-removal of asbestos paper from ingot bottoms prior to lathing. Also, any excess or embedded asbestos not removed by hand is dislodged during the lathing operation. There are also numerous uses in the potrooms. Pot repair personnel should be checked for asbestos exposure. Those employees involved in future demolition of the N-40 potline should also be checked for asbestos exposure. / a :> j ARCH 18627 ATTACHMENT II Page 3 ASBESTOS (Cont.) Personal samples of employee exposures taken in 1978 May of asbestos fibers in the Marinite finishing room and at the lathing area showed levels below the allowed 2 fibers/cc air, but above the 0.1 fibers/cc action level set by OSHA. The Asbestos Standard requires personal monitoring every 6 months to document exposures in areas where asbestos is used. In addition, annual medical examinations are required for all employees in occupations exposed to airborne concentrations of asbestos fibers regardless of the concentration. The Standard also details methods of clean-up and disposal of asbestos materials. ? #### ARCH 18628 ATTACHMENT III MASSENA WORKS WALK-THROUGH INDUSTRIAL HYGIENE SURVEY 1978 JUNE 07-09 Areas and operations with potential exposure that require evaluation are as follows: AREAS & OPERATIONS POTENTIAL EXPOSURES SMELTING Carbon Plant - Unloading and transfer of coke and liquid pitch Dust; Coal Tar Pitch Volatiles - Mixing - Press and Vibrators - Crusher - Ball Mill - Furnace - Rodding Coal Tar Pitch Volatiles; Dust Coal Tar Pitch Volatiles Noise; Dust Noise; Dust Coal Tar Pitch Volatiles; SO2; Dust 1,1,1-Trichloroethane; Noise; Dust; Ventilation at furnaces Potrooms Maintenance personnel should be monitored for the contaminants in area where they work. - Filling buckets with fluoride and alumina Fluoride; Total dust - Proper shield placement on pots Pot Repairs S2 - Pot digging Fluoride dust; Nuisance dust; NH^; Phosphine (?); Noise - Pot straightening Fluoride dust; Noise - Pot welding Fluoride; Local exhaust ventilation - Pot relining Coal Tar Pitch Volatiles from hot seam mix; Potential asbestos exposure in demolition of N-40 potline; Silica in pot relining from insulation. ARCH 18629 ATTACHMENT III Page 2 MASSENA WORKS WALK-THROUGH* INDUSTRIAL HYGIENE SURVEY 1978 JUNE 07-09_______________.___ Areas and operations with potential exposure that require evaluation are as follows: AREAS & OPERATIONS______________________ POTENTIAL EXPOSURES SMELTING (Cont.) Bath Crusher - Trucks; Housekeeping Fluoride; CO Butt Cleaning Machine Shop Garage - Battery charging area Aluminum Shipping - Trucks loading rail cars * INGOT PLANT Furnace Area - Casting Pits * - Pits - Eating areas in pits - Emergency respirators-MSA Type N gas masks with acid gas canisters in each casting pit - Catastrophic chlorine spills - Casting pits Fluoride; Noise Welding fumes; Check local exhaust ventilation; 1,1,1-Trichloroethane degreaser; asbestos. Carbon monoxide (in winter?); Mineral spirits General ventilation Carbon monoxide * ~ No chlorine or sulfur dioxide noted; Check during winter months. Asbestos Poor housekeeping Need to be cleaned; Uses need to be reviewed; correct labeling required, i.e., "Escape Mask Only". Review procedures for Ingot Plant personnel action during such situations. Application of Tarset for solvents ARCH 18630 ATTACHMENT III Page 3 MASSENA WORKS WALK-THROUGH INDUSTRIAL HYGIENE SURVEY 1978 JUNE 07-09 Areas and operations with potential exposure that require evaluation are as follows: AREAS. & OPERATIONS______________________ POTENTIAL EXPOSURES INGOT PLANT (Cont.) Skim Reclamation - Skim cooled in room; transferred to railroad car Mold Assembly Room - Hand-Finishing Marinite molds Extrusion Area Chlorine Vaporizer Area ** Dust Asbestos; 1,1,1-Trichloroethane degreaser Glastic block fumes (secure Material Data Sheet from manufacturer); Oil mist (?); Poor housekeeping in area; Asbestos Chlorine gas; Chlorine spills -- Post emergency procedures; Air respirators --'"Check supplies periodically; Emergency teams retrained semi-annual3y4 Review Engineering Standard 18.12, 7 Safety & Health in Chlorine Operations * FABRICATION AREAS Machine Shop - Welding stations - Small lead pot Motor Repair Trichloroethylene degreaser Local exhaust ventilation should be used Check Pb concentration and ventilation of hood Trichloroethylene degreaser; Insulating paint booth & curing ovens; Paint ARCH 18631 ATTACHMENT III Page 4 MASSENA WORKS WALK-THROUGH INDUSTRIAL HYGIENE SURVEY 1978 JUNE 07-09__ Areas and operations with potential exposure that require evaluation are as follows: AREAS & OPERATIONS POTENTIAL EXPOSURES FABRICATION AREAS Central Garage (Cont.) Accessory Finish - Core making sand - Hand molding - Automatic molding machine - Core knockout - Welding fumes Carbon monoxide (in winter); Cleaning solvent (?) Occasional use of asbestos paper Silica; by-products of core making materials Dust Noise; Dust Silica; Noise 0, (continue attempts to reduce Jlevels) - Cadmium-zinc brazing Merchant Mill - Wire redraw area - Inert gas furnaces - Spooling aluminum welding wire - Caustic dip operations Building 140 - Caustic dip operations - Continuous mill Cable Mill # # # Not used for 2 years; check fumes if used in future Noise Carbon Monoxide 1,1,1-trichloroethane; Isopropyl alcohol Caustic fumes; Oxides of nitrogen; Check ventilation periodically Caustic fumes; Oxides of nitrogen; Check ventilation periodically Oil mist Noise ARCH 18632 # FROM: R. K. MDBROW TO: MEMORANDA y'J 1978 May 04 Industrial Hygiene because.it is concerned with employee safety is the responsibiity of the Safety Department at Massena Operations. The hygiene effort here has historically been an intermittent one with area surveys being dene and action being taken on an emergency or call-in basis. In this age of OSHA regulations for industrial exposure requiring surveys, record keeping and medical examinations we must have an organized .ongoing hygiene program. ; With this in mind I have decided to reactivate the Operations' Industrial Hygiene Ccninittee which will be charged with the following: 1. Become familiar with and stay abreast of existing and proposed Industrial Hygiene Regulations. 2. Identify present and future problems. 3. Provide feedback to operating and staff personnel on problems and regulations. 4. Make reconmendations to management for necessary action and follow-up to completion. 5. Assist in education of personnel on good work habits and correct use of protective equipment. Tne members of the Committee are as follows: Safety Manager Chief Met. Tech. Coord.-Potrooms Ps. K. Morrow -J. G. Sutton -N.. Wells Chairman Secretary Chem. Lab. Supv.-I.H. G.- D. Hides Prod. Eng.-Ingot W. T. Burt Safety & Security Supv P. T, T. A. Reine Chief Mech. Engr.-Fab. R. K. Brown Plant Physician -Dr. M. J. Elder Env. Control Supt. ?. F. Woodward The first meeting win -be held on Wednesday, May 10 at 3:00 P.M. in the Main Office Conference Room; Carmittee members, please send me before that time any thoughts on Industrial Hygiene or problems you have recognized in the plant. 9 * R. K. MORRCW RKM:bl Cc: Managers Members of Caimittee abch 18633 ATTACHME Sampling Pumps Make/Model Quantity USA Model G SKC Model 222-3S1 r. ' Pulse Pump, Environmental Measurements, Inc. 3 3. 1 Respirable Dust Samplers Type MSA 10 mm nylon 3 Impingers and Bubblers Type Standard Impingers Standard Impingers as Bubblers Midget Impingers Fritted Glass Bubblers 30 10 9 6 Noise Measurement Equipment Type GR 1933 Octave Band Analyzer GR 1562-A Calibrator GR 1558-BP Octave Band Analyzer Dupont D-100 Dosimeter (90 dBA cutoff) 1 1 1 2 *In process of trading the two D-100's for five D-376 with 85-90 dBA cutoff. Detector Tubes and Pumps Drager and MSA pumps with an assortment of detector tubes. Direct Reading Instruments Type Model Contaminant Ecolyzer Ecolyzer 2100 2900 MSA Combustible Gas MSA Combustible Gas 0/2 Edmont Oxygen MSA Nitrogen Dioxide Unit (Old - not used) 40 250 CO, 0-100 ppm CO, 0-250 ppm 0-2500 ppm Combustibles Combustibles and 0 % o2 ARCH 18634 ATTACHMENT I (Continued) 7. High Volume Samplers Gelman Model 1600-3-1 8. Ventilation and Heat Stress Equipment Rotating Vane Anemometer Anemothern Smoke tubes Various pitot tubes and manometers 1 equipped heat stress stand Bendix Psychron 9. Analytical Balance Mettler H-51, 5 place Quantity r / ARCH 18635 IT ATTACHMENT v* Audiometry The Medical Department is equipped with an audiometer and audiometric booth. The four nurses who perform audiometric tests have been certified within the last four years at Environmental Hearing and Vision Consultants, Syracuse, New York, with one________ recertified by HCNC recently. Audiometric testing is performed as part of pre-employment physicals and on all production employees at the time of their periodic physicals ( approximately 3 years). Salaried personnel over 40 years of age receive annual physicals including audiometric tests. HCNC made their initial visit to Massena on June 5-6, 1978 and has submitted recommendations on the hearing conservation program. Noise Noise exposures are one of the most frequently encountered problems throughout the works, especially in the fabricating areas. A plant-wide htrr* Kcljj , noise survey hao jfrqjf-feegn performed-afc--Oipy^egnune.1 lie ^ F^Uou^ia. vU. Cor*-} nTM i 1 ............ 1 m wniUin-r n-P wr_ n n fciiw. Vn nn-THTTOopH in ordpr tn Turni-ili lufuimaLiou Lu ungliiLLi lug fui nuise 'crniUol. After comple rof an engineering project, noise measurements are made to determine the effectiveness of the noise controls. Plans for an annual noise survey of the plant are being developed and will be followed by dosimeter studies in borderline noise areas. jfBT ^ogfilbil ity of lining-summer hglp._ti%-*vwrtnr^-*hr>-currTrY ^ un^f-r. -^eoTTKldei iin.Tr.,_",|.uMmuu*ii ARCH 18636 smm or ATTACHMENT JStT (Contd. - Page 2) Chlorinated Hydrocarbons Vapor degreasers using 1,1,1-trichloroethane (methyl chloroform) and trichloroethylene as solvents are found throughout the plant. Testing on the degreasers has been done in the past using detector tubes; however, because of the recent attention given to the potential health hazards associated with the use of chlorinated hydrocarbons, it is important that sufficient personal sampling be conducted at the vapor degreasers to document the time-weighted-average (TWA) exposures of the operators. 'i^recommencki.that sampling be conducted twice per year, once in the summer when the buildings are open and in the winter with the buildings closed. Asbestos -- Potential exposures to asbestos fibers exist at the following locations in the Ingot plant: (1) the mold assembly room, (2) the casting.and soaking pits, and (3) the ingot lathing area. Marinite headers are pre-cut by an outside concern, minimizing dust exposure; however, dust is produced during hand finishing and assembly operations in the mold assembly room. Exposure to asbestos fibers exists during the hand-removal of. asbestos paper from ingot bottoms prior to lathing. Also, any excess or embedded asbestos not removed by hand is dislodged employee exposure taken in 197^ May fibers in the marinite finishing rooiu and at the lathing area showed I \tdtA OSlfA. Levels below the allowed 2 fibers/cc ail/'. The asbestos, standard requires personal monitoring every 6 months to document exposures >in ARCH 18637 ATTACHMENT I(Contd. - Page 3) areas where asbestos is used. In addition, annual medical examinations are required for all employees in occupations exposed to airborne concentrations of asbestos fibers regardless of the concentration, The standard also details methods of clean-up and disposal of asbestos materials. {'! / I-' ARCH 18638