-------
                                  EPA-340/1-85-002a
Air Pollution Source  Inspection
          Safety Procedures

            Student Manual
                     Prepared by

                    John Richards
                     Robin Segal
                Engineering-Science, Inc.
                  501 Willard Street
                  Durham, N.C. 27701
                Contract No. 68-01-6312
                    Task No. 126
              EPA Project Officer: John R. Busik
              EPA Work Assignment Managers:
                     Elva Slagle
                     Kirk Foster
                    Prepared for:

            Occupational Health and Safety Staff
                Office of Administration

                       and

            Stationary Source Compliance Division
          Office of Air Quality Planning and Standards
            U.S. Environmental Protection Agency
                Washington, DC 20460

                   September 1985

-------
                               INTENDED PURPOSE
     This is not an official policy and standards document.  The opinions,
findings, and conclusions are those of the authors and not necessarily those of
the Environmental Protection Agency.  Every attempt has been made to represent
the present state of the art as well as subject areas still under evaluation.
Any mention of products or organizations does not constitute endorsement by the
United States Environmental Protection Agency.

     This document is issued by the Stationary Source Compliance Division,
Office of Air Quality Planning and Standards, U.S. EPA.  It is for use in
workshops presented by Agency staff and others receiving contractual or grant
support from the U.S. EPA.

     Governmental air pollution control agencies establishing training programs
may receive single copies of this domument, free of charge, from the Stationary
Source Compliance Division Workshop Coordinator, U.S. EPA, MD-7, Research
Triangle Park, N.C. 27711.  Since the document is specially designed to be used
in conjunction with other training materials and will be updated and revised
periodically as needed, it is not issued as an EPA publication nor copies
maintained for public distribution.
                                      ii

-------
                               TABLE OF CONTENTS

Lecture

   1.  INTRODUCTION

   2.  WALKING AND CLIMBING HAZARDS

   3.  HAZARDS TO VISION AND HEARING

   4.  BURN, ELECTRICAL AND EXPLOSION HAZARDS

   5.  HEAT AND COLD STRESS

   6.  INHALATION HAZARDS

   7.  SPECIAL INSPECTION SAFETY PROBLEMS

   8.  SAFE USE OF PORTABLE INSPECTION EQUIPMENT

   9.  AGENCY SAFETY PROGRAMS


   APPENDIX A  BIBLIOGRAPHY

   APPENDIX B  REVIEW QUESTIONS AND ANSWERS

   APPENDIX C  EXAMPLE OF ONE PLANT'S SUBSTANCE
               EXPOSURE SYMPTOM CHART

   APPENDIX D  EXAMPLE HAZARD REPORTING FORM

   APPENDIX E  EPA RESPIRATORY PROTECTION PROGRAM GUIDELINE
Page Number

    1

    7

   45

   57

   71

   83

  131

  137

  149


  153

  157


  169

  177

  181
                                      iii

-------
                                  DISCLAIMER
     The safety precautions set forth in this manual and presented at any
training or orientation session, seminar, or other presentation using this
manual are general in nature.  The precise safety precaution required for any
given situation depends upon and must be tailored to the specific circumstances
or each situation.  Engineering-Science, Inc. expressly disclaims any liability
for any personal injuries, death, property damage, or economic loss arising
from any actions taken in reliance upon this manual or any training or
orientation session, seminar, or other presentation based upon this manual.
                                      IV

-------
                               ACKNOWLEDGEMENTS


     The U.S.  FPA Project Managers were Ms.  Elva Slagle and Mr.  Kirk Foster.
The authors sincerely appreciate their assistance and interest in this project.
The Engineering Science Project Manager was Ms.  Robin Segall and she was aided
by Ms. Gale  McCorraick.   A portion  of this document was prepared by  Richards
Engineering under subcontract to Engineering Science, Inc.  The Project Manager
at  Richards Engineering was  Dr. John R. Richards, P.E.     Ms. Kathz Butz  of
Graphic Associates prepared the drawings for this manual.

     Engineering  Science  and Richards Engineering would like to thank the  15
companies who permitted photographs to be taken of their air pollution  control
systems.   We  sincerely  appreciate the considerable support they provided  in
obtaining the necessary photographs.   We would also like to thank Mr.  Jim Orr
of the Pennsylvanin Department of Environmental Resources and Mr. John Reggi of
the  West  Virginia Air Pollution Control Commission for their help  with  this
project.

-------
SLIDE 1-1
                                       This  program  is designed to  help  air
                                       pollution  control equipment  inspectors
                                       recognize  and avoid common  health  and
                                       safety  hazards.   The  slides shown  in
                                       Lecture 1 introduce the major categories
                                       ies of hazards encountered in industrial
                                       facilities.
SLIDE 1-2
                                       Walking  hazards  are one of   the  major
                                       causes  of  accidents  involving    field
                                       inspectors.  This slide illustrates  a  two
                                       foot  drop along  an elevated catwalk.

-------
SLIDE 1-3
                                       The  icy surface shown in this slide  is
                                       another common walking hazard.   A  fall
                                       in  this  area could easily result in  a
                                       serious head injury.
SLIDE 1-4
                                       The inspection of air pollution  control
                                       equipment  often  involves  climbing  of
                                       ladders.    Proper  ladder climbing prac-
                                       tices are mandatory.

-------
SLIDE 1-5
                                       Extended   exposure  to  high  noise   levels
                                       can lead  to  gradual hearing loss.  Hear-
                                       ing protection  is often  advi
SLIDE 1-6
                                       Most  metallic  surfaces  in air  pollution
                                       control  equipment  are very hot.   Direct
                                       contact  can  lead to a painful burn.

-------
SLIDE 1-7
                                       Improper handling of flammable liquids
                                       can result in an explosion.
SLIDE 1-8
                                       Inhalation  hazards are often present in
                                       the  vicinity of the air pollution  con-
                                       trol systems and other areas which  must
                                       be inspected.

-------
SLIDE 1-9
    FACTORS CONTRIBUTING TO
  POTENTIAL INSPECTION SAFETY
             PROBLEMS
 ' Lack of personal safety equipment
 > Lack of familiarity with plant hazardous locations: trip
   hazards, overhead obstacles, equipment movement
   areas, and partially confined areas
 • Synergistic effects due to the accumulation of numerous
   pollutants
 > Lack of acclimatization to heat
A number  of factors increase the inspec-
tor's   risk  with regard  to  health  and
safety  hazards.   These  factors are in-
troduced  in the next  two  slides.   These
are discussed in more detailed  through-
out the program.
 SLIDE 1-10
 FACTORS CONTRIBUTING TO POTENTIAL
    INSPECTION SAFETY PROBLEMS
              (continued)
• Potential sensitivities to pollutants and materials which
  are encountered
• Attempts of plant personnel to hurry Inspector
• Lack of safety considerations due to conversations with
  plant personnel
• Lack of inspector training
• Lack of medical monitoring program.
The   purpose of  these last two  slides is
to   convince field  inspectors that  they
are   not  immune to health  and   safety
problems.

It is  important that  field   personnel
exercise  care while performing  inspec-
tions of air pollution control  systems.
Each  inspector  must  be aware  of  and
adhere  to all agency and  plant   safety
policies.   Furthermore,  the field work
should  be conducted only if the  inspec-
tor  is in good physical condition.

All  personnel involved in the inspection
of   air pollution control sources should
have formal training in safety   policies
and    procedures before  beginning  the
field work.   This  course is intended to
supplement this  formal training.

-------

-------
SLIDE 2-1
                                    This  lecture concerns the  numerous
                                    physical  hazards which can be found
                                    while  walking to or working  around
                                    air pollution control  systems.  The
                                    list presented in the adjacent slide
                                    presents some of the most common and
                                    potentially  dangerous conditions.

                                      A  number  of slides are  presented
                                    to  illustrate the importance of the
                                    safety  procedures mandated  by  EPA
                                    Policy  and  described in the  refer-
                                    ences listed earlier.
     The  risk of accidents due to these conditions  can be minimized by ad-
herence  to basic safety procedures and by  common  sense.   Unfortunately,
some  inspectors can get distracted while conducting the inspection.   This
can  occur due to general unfamiliarity with the plant or due  to  conver-
sations  with  the plant personnel.   Accidents are  more  likely when  the
inspector forgets  to look for the physical hazards.   These problems  are
avoided by conducting the inspection at A CONTROLLED PACE.
SLIDE 2-2





         >

                   	
      WALKING  &
      WORKING
Source: National Audiovisuals Center
Slippery areas are very common  near
air  pollution control  systems.   A
fall  can result in serious injuries
to  the head or other parts  of  the
body.  These areas should be avoided
to  the extent possible.   If it  is
necessary  to  go  through  slippery
areas,  the  proper type  of  shoe
should be used.

It  is not always possible  to  see
that an area is slippery.   The sur-
faces of some sludge and,  wet fiber
layers often disguise  the  slippery
nature of the material.  Even ice is
hard to identify in some cases.
     The inspector should be  looking for slippery areas (1) around all wet
 scrubber systems,  (2) while  walking on any  surface which  could have oil  or
 grease deposits, or (3) while walking on any settled deposits.


-------
SLIDE 2-3
                                       During  the inspection of wet scrub-
                                       bers  and  other  control   systems,
                                       there  is a natural tendency to look
                                       around  or up at the various  system
                                       components.   Falls can easily occur
                                       on  the  slippery  areas  which  are
                                       often beneath these systems.

                                       This slide shows the area around the
                                       main  recirculation  purnp of  a  wet
                                       scrubber.   The entire area is  very
                                       slippery.   A fall here could result
                                       in a head injury on one of the foot-
                                       ings shown in the slide.

     Most  centrifugal  pumps  suffer some leakage due  either  to  packing
problems  or to the packing seal water.   If it is not adequately  drained,
the  area  around the pump can be very wet.   This particular  system  also
suffered  an  occassional recirculation tank overflow because  of  foaming.
This  deposited  wet  fibrous material on most of  the  walkways  near  the
scrubber.   Although the entire system could not be shown on this slide, it
was possible to avoid this wet area without limiting  the inspection.
SLIDE 2-4
                                       This  is a view of the area under an
                                       electrostatic precipitator serving a
                                       pulverized coal-fired boiler.  It is
                                       very  common to find solids deposits
                                       in  this area because of the  occas-
                                       sional  need to clean out one of the
                                       hoppers.  Small puddles of water re-
                                       maining after a rain can make this a
                                       treacherous walking surface.   There
                                       are   numerous   pipes,    conduits,
                                       valves,  and  beams  throughout  the
                                       area and this makes any fall  parti-
                                       cularily  dangerous.   It should  be
                                       assumed  'chat  all areas  underneath
                                       hoppers  are slippery and thus  they
                                       should be approached cautiously.

     Later in the lecture other potential problems which can be encountered
under hoppers will be discussed.   These include hot,  free flowing solids,
high concentrations of toxic gases,  and hot surfaces.    Obviously, hopper
areas  must be approached carefully.   They should not even be entered  un-
less  the inspection data gathered during the initial phase of the  inspec-
tion clearly illustrates the need for information concerning the hoppers.


-------
SLIDE 2-5
                                       This  is  a railcar  unloading  shed
                                       which is equipped with a baghouse to
                                       control  the  lime unloading  opera-
                                       tion.  One of the ways to get to the
                                       baghouse passes by the track and car
                                       puller shown in this slide.    If the
                                       cable  shown snapped while a  person
                                       was  walking  along  this  track   a
                                       severe  injury  would  be  possible.
                                       Inspectors  should avoid the area of
                                       the  car  puller when the  cable  is
                                       under tension.

                                       In this case, the unloading shed can
                                       be  approached  from  the   opposite
                                       direction.
     Rail  sidings  are commonly visited by inspectors since many  of  them
have  small baghouses on the loading and unloading  operations.    They  are
also  used  occassionally  as vantage points for  making  visible  emission
observations.  It is best to avoid these sidings to the extent possible.
SLIDE 2-6
                                       Another rail car unloading operation
                                       is shown in this slide.   Inspectors
                                       should  not  walk between  the  cars
                                       since  these trains are often remote
                                       controlled and can move without  any
                                       warning.   The  operator may not  be
                                       aware  of the presence of people and
                                       may  not be able to see everyone  in
                                       the siding area.

                                       As a general rule, inspectors should
                                       allow  75  foot clearance  from  any
                                       stopped  engine  or   cars.    Also,
                                       visible emission observations should
                                       not  be  made while standing on  the
                                       tracks.

-------
SLIDE  2-7
Source: National Audiovisuals Center
While walking around the plant  area
the inspector should be conscious of
moving  equipment such as  forklifts
and cranes.   The operators  usually
are careful,  however,  they may not
be  aware  that  someone is  in  the
area.

This problem has become more  common
lately as some plants reduce or turn
off the plant lights to save energy.
These  plants may conduct operations
only at night and have just a  small
crew  in the plant during the normal
working  hours.    Plant   personnel
operating  forklifts  do not  expect
anyone  to be in the plant  and  can
not see very far ahead.
     In such cases,  the inspector and plant representative (if any) should
try  to  reach the air pollution control equipment by walking  outside  the
plant buildings.   If this is not possible, the inspector should be careful
while walking through the plant.
SLIDE 2-8

                                       This  is  the first of a  series  of
                                       three slides of a venturi-rod scrub-
                                       ber installation.   The weather con-
                                       ditions  during the inspection  were
                                       less than ideal.

                                       The  vantage point of this slide  is
                                       the one that would be chosen by  the
                                       inspector to make a visible emission
                                       observation (if it was not snowing).
                                       There  is  obviously a  considerable
                                       amount  of sludge  surrounding  this
                                       area.   This sludge is common at the
                                       plant except during very dry periods
                                       or when the scrubber is down.
     The  inspector  would have to be careful to watch where he or  she  is
walking while choosing a site to make the visible emission observation.  In
some cases,  the inspector becomes preoccupied with checking for the proper
sun angle and the wind direction and forgets about the slippery surface.
                                      10

-------
SLIDE 2-9

                                       This is a view of part of the system
                                       from  approximately the same vantage
                                       point as the last slide.   There is a
                                       settling basin close to the location
                                       where a visible emission observation
                                       would  be made.   This has a  ground
                                       level  entry  and a steep  slope  to
                                       permit  front end loaders  to  clean
                                       out  the accumulated sludge when the
                                       basin is emptied.   It would be easy
                                       to  slip into this pond.

                                       This style of settling basin is very
                                       common.   It is the preferred  basin
                                       design  in many cases because it  is
                                       easy  to  clean  out  and  has  good
                                       settling properties.

      The  areas immediately around this basin or any settling pond  should
be avoided by the inspector.   Samples of the liquor should not be obtained
at  this location since it is usually much safer and easier to get  samples
of  the  pond or basin liquor from sampling points downstream of  the  main
pump.
SLIDE 2-10
                                       This  is  a  view of the  same  area
                                       shown in the previous slide.  It was
                                       taken 15 seconds after the  previous
                                       slide.   A  large  steam  cloud  has
                                       almost  entirely obscured the  loca-
                                       tion  of the settling pond.   An un-
                                       suspecting  inspector who is  moving
                                       too fast could easily get too  close
                                       to  the  entry  to the  basin  under
                                       these conditions.
                                       It  is  common for steam  clouds  to
                                       intermittently  "mask"  the  walking
                                       surfaces  around air pollution  con-
                                       trol systems.   The inspector should
                                       not proceed until there is  adequate
                                       visibility.

     Some  inspectors  make the assumption that they are familiar with  the
obscured area and can therefore proceed.  This can be a very bad assumption
since  plant personnel may have forgotten to replace a grating,  have  left
some rope or other obstacles,  or made other changes.  An inspector usually
visits a plant only once or twice a year.   Many changes can occur  between
inspections.
                                      11

-------
SLIDE 2-11
 Source: National Audiovisuals Center
Up  to this point every slip  hazard
has  been wet.   There are  numerous
other slippery areas caused by  oil,
grease,  or solids.   This slide il-
lustrates  a small quantity of  very
slippery   "marble"  type  deposits.
This area could be easily avoided as
long as the inspector (and the plant
personnel  accompanying the  inspec-
tor)   were  looking  for   slippery
areas.

Another  common  cause  of  slippery
areas  is oil or grease leaking from
moving machinery.
     The  best way to minimize the risk from these types of deposits is  to
avoid  rushing  during the inspection.   In some cases,  the  inspector  is
anxious to get to a malfunctioning control device.   Also,  some plant per-
sonnel  are  anxious to get the inspector "out the door" so that  they  can
continue  with their work.   It is the responsibility of the  inspector  to
make  sure  that the inspection is conducted at a controlled pace  so  that
this type of accident does not occur.

SLIDE 2-12
                                       This a photograph of a small reverse
                                       air  fabric  filter.    The  ambient
                                       temperature  during  the  inspection
                                       was  approximately  20°F and it  had
                                       snowed  three  days  earlier.    The
                                       weather  conditions created  several
                                       slip hazards.

                                       Prior to starting the inspection  of
                                       this  system  (or any system) it  is
                                       important  to survey  the  situation
                                       for slip hazards and all other types
                                       of potential problems.   The inspec-
                                       tion  should then be conducted in  a
                                       manner  which minimizes these poten-
                                       tial  problems.    If it can  not  be
                                       done safely at the present time,  it
                                       should be terminated.

     In  this case,  only part of the inspection could be safely done.   It
was possible to check the opacity of the filter discharge and the  adequacy
of  the solids discharge system operation.   It would have been possible to
check the pressure drop safely,  however,  the gauge was not working.   The
use  of portable instruments would not have been safe at this unit on  this
day.   Furthermore,  the inspector should not have gone up to the  platform
surrounding  the collector compartments.   The potential problems here  are
shown in the next few slides.
                                     12

-------
SLIDE 2-13

                                       This is a view of the ground next to
                                       the  platform  access  ladder.     It
                                       would be easy to slip on the ice and
                                       hit   one's  head  on  one  of    the
                                       footings shown in the slide.   There
                                       was also a lot of debris around this
                                       area  which  could make any  fall  a
                                       serious problem.  This is one of the
                                       reasons  that the  inspector should
                                       not go up the ladder on this day.

                                       This ice is relatively easy to  spot.
                                       In  some cases,   it is not quite  so
                                       obvious that the area is slippery.
SLIDE 2-14
                                       This  is the wooden platform  around
                                       the fabric filter compartment.   The
                                       mound  of ice made getting  traction
                                       very  difficult.    In addition to  a
                                       simple  fall on the platform,   it is
                                       conceivable (but  not likely) that  a
                                       person could slip under the mid rail
                                       and  fall  to the ground due to  the
                                       lack of a toe guard on the railing.

                                       Due  to the ice in this location  it
                                       is  unadvisable to continue the  in-
                                       spection.    In   this   case,   the
                                       portable  instruments could  not  be
                                       used  to check the pressure drop and
                                       the clean side deposits could not be
                                       evaluated.

     It would be impossible to see this ice from the ground.  Upon reaching
the  top  of  the access ladder the inspector  should  determine  that  the
surface is not adequate and proceed directly back down.

     This  is a common problem with fabric filters mounted on the roofs  of
silos and other flat surfaces.  These units can be 50 to 150 feet above the
ground and a fall could be very serious.   It is especially difficult  to re-
move  an injured person (eg.  broken leg,  sprained ankle) from these  high
locations.
                                      13

-------
SLIDE 2-15
                                       This  is a view of a railroad siding
                                       next to a fabric filter system.   It
                                       is  apparent that there is some  ice
                                       approximately 15 feet  ahead.   What
                                       may  not  be  apparent is  that  the
                                       entire area is slick.   The area  in
                                       the  foreground is "black ice".   It
                                       seems  slipperier than  the  regular
                                       ice  in the background of the slide.
                                       The  "black  ice" is  simply  frozen
                                       water  having a very high  suspended
                                       solids content.

     While  looking  up at the rail car loading shed baghouse it  would  be
easy to miss this very slippery area.   It must be relatively cold for this
ice to form.  The day this photograph was taken the temperature was 8°F.
SLIDE 2-16
                                       This  is  a  venturi  rod   scrubber
                                       mounted  on  a horizontal  roof.   A
                                       small puddle of water on one side of
                                       the  unit has  frozen.   There  were
                                       several sharp corners which might be
                                       hit during a fall.
                                       This  is  the most direct path  from
                                       the access ladder to the location of
                                       *•"--  differential  pressure  gauges,
                                       the
                                                                         to
                                       However,  there  was another way  uu
                                       reach  the gauges without having  to
                                       worry about the ice.

     During  cold  weather it should be assumed that  almost  all  elevated
horizontal  surfaces will have some frozen puddles or other slippery areas.
Since some of these surfaces do not have guard rails,  it is  particularly
important to avoid the slippery ones.
                                     14

-------
SLIDE 2-17
                                       This  is  a  plank leading   from  an
                                       access ladder over to the area of  a
                                       flooded disc scrubber.   The roof has
                                       some ice and there is no guard rail.

                                       It  is  important to  be especially
                                       careful  of slip hazards on elevated
                                       surfaces.  Falls from these surfaces
                                       can be fatal.   Many of the elevated
                                       surfaces were not intended  for walk-
                                       ing, therefore guard rails  are often
                                       missing.  Some of these surfaces are
                                       also sloped.
     There  is no guarantee that the temporary plank or other walking  sur-
face  is free from ice or water.   In the case shown above,  the board  was
moderately slippery due to water which had dripped off an adjacent roof and
refrozen over night.  Deposits of fugitive materials on the plank also made
the walkway slippery.
SLIDE 2-18

                                       This is a temporary walkway over  an
                                       excavated area.  It is probably safe
                                       as  long as (1) it is in regular use
                                       by  plant personnel,  (2)  the  wood
                                       appears to be in good condition, and
                                       (3) the ends will not slip.   Never-
                                       theless,  it  is a good practice  to
                                       let  the plant representative  along
                                       on  the inspection go first.   Also,
                                       no  more than one person at  a  time
                                       should cross this temporary bridge.

                                       Occassionally,  these might be found
                                       in remote areas of the plant.  It is
                                       possible   that  the  wooden  planks
                                       have  rotten or that the ends are no
                                       longer secured. The integrity of the
                                       walkways should be questioned and it
                                       should be avoided if possible.

     Under  no circumstances should an inspector cross between two platforms
or   buildings (or any other crevice) by means of a ladder or single  plank.
Ladders  are  not intended for this service and are sometimes  not  secured
properly.    The  inspector should refuse to cross any  potentially  unsafe
walkway  (such  as a ladder,  a single plank,  or a weakened bridge) even if
the  distance is short or plant personnel insist.
Source: National Audiovisuals Center
                                      15

-------
SLIDE 2-19
                                       Before  going  up  to  any  elevated
                                       platform around an the air pollution
                                       control system, the integrity of the
                                       platform  should be quickly  checked
                                       from the ground.   This is a view of
                                       the  wooden walkway on the  baghouse
                                       shown earlier.  The condition of the
                                       boards  and the support angle  irons
                                       should  be  checked before  climbing
                                       the ladder up to the platform.  Once
                                       you are on the platform,  it is very
                                       difficult  to  confirm  that  it  is
                                       structurally secure.

                                       Some  of the common problems include
                                       rotting of the wooden  boards,  cor-
                                       rosion   of  metal   walkways,   and
                                       failure of the supports.
                                       This  is  the walkway around  a  new
                                       pulse jet baghouse.   Both the walk-
                                       way  and the supports appear  to  be
                                       very secure.
                                     16

-------
SLIDE 2-21

                                       Before  moving to an  elevated   plat-
                                       form  the inspector should  also con-
                                       sider  whether  there is  a   risk  of
                                       being trapped  on the  platform   while
                                       a  rising cloud of toxic  gas or high
                                       temperature steam passes.   If  so,
                                       the  inspection should only be   con-
                                       ducted when the source of the gas or
                                       steam is not on.  In  some cases, the
                                       inspector may  be able to  use a   res-
                                       pirator   and/or  some  protective
                                       clothing  if  the process  equipment
                                       must   be   operating   during    the
                                       inspection.

     There  are some cases where an inspection can not be done safely   with
or without protective equipment and clothing.  In such cases, the  inspector
must  be  content with simply evaluating emissions from a distance or  the
evaluation of instrumentation located in safe areas.

     Inspectors  should not underestimate the potential problems  resulting
from rising steam clouds and/or toxic clouds of pollutants.    They can form
suddenly  due to a process upset and it is difficult  to get  off  a   platform
when  both visibility and breathing is impaired.   Several  inspectors   have
been very seriously hurt due to this problem.
SLIDE 2-22
                                       This  is  a typical roof at a  manu-
                                       facturing  facility.   It  would  be
                                       necessary to be on this roof to read
                                       the  visible emissions  coming  from
                                       the  various small vents.   A  quick
                                       shift  in  the wind direction  would
                                       result  in  the  fumigation  of  the
                                       inspector.  The bluish white aerosol
                                       could  contain some very  toxic  and
                                       irritating materials.  The inspector
                                       must  know  ahead of time what  pos-
                                       sible  pollutants are in  the  plume
                                       and  carry with him the  appropriate
                                       type   of    respirator   for   this
                                       material.
     The  position  used  for the visible emission  observation  should  be
normal to the wind direction.  This places the inspector in the direct line
of travel of plumes from other process vents or discharge  points.   Before
selecting  a location for the observation,  the locations of all  discharge
points (both continuous and intermittant) should be determined.
                                     17

-------
SLIDE 2-23
                                       ilegardless  of the apparent strength
                                       of an elevated platform,   large num-
                                       bers  of people should not be on  it
                                       platform  at one spot.
SLIDE 2-24
                                       There  are  some  elevated  surfaces
                                       which  may not be able to  withstand
                                       any  additional load.   An inspector
                                       who walks across a roof as shown  in
                                       this slide may fall through.   It is
                                       very  important that inspectors only
                                       walk in areas designated as safe  by
                                       the plant personnel.  This is one of
                                       the  reasons  that it  is  essential
                                       that  plant personnel accompany  the
                                       inspector.   It  is prudent for  the
                                       inspector  to walk behind the  plant
                                       personnel.

     Plants  may replace sections of worn corrogated metallic roofing  with
FRP corrogated roofing.   The latter does not usually have the load bearing
capability of the metallic roofing,  therefore, an inspector walking across
a supposedly secure roof could fall through.  While the FRP material should
be  easy to identify,  in the many cases a thin layer of fugitive  material
(as  shown  in the above slide) can easily disguise it.   This  is  another
reason that the plant representative should accompany the inspector.
                                     18

-------
SLIDE 2-25
                                       One  sign of potential  roof   loading
                                       problems  is  the presence of  large
                                       deposits  of solids or   snow.   This
                                       can render an otherwise secure   roof
                                       into  a major hazard,   especially in
                                       the immediate vicinity  of the solids
                                       deposits.

                                       The  deposits  shown in  this  slide
                                       were  due  to  the clean  out  of  a
                                       plugged  hopper on a baghouse  which
                                       is  up and to the right of the   view
                                       of the slide.    The area near  these
                                       deposits should be avoided if at all
                                       possible.
SLIDE 2-26
                                       Not  all  guard  rails  on  elevated
                                       platforms  and walkways can actually
                                       withstand  the 200 pound  force  for
                                       which  they were designed.   Leaning
                                       against weak railing could result in
                                       a  serious   accident.    Inspectors
                                       should check the integrity of  these
                                       railings,  if  possible.   Under  no
                                       circumstances  should the  inspector
                                       risk  a fall,  however,  in order to
                                       check  the  adequacy  of  the  guard
                                       rail.

                                       This  railing was next to a  venturi
                                        si  rubber.   An  inspector  may  have
                                        been  tempted  to lean against  this
                                        j ailing  in  order to see  the  main
                                        pump and the static pressure gauges.
                                       This railing was very weak.
                                     19

-------
SLIDE 2-27
                                       This  photograph shows an  inspector
                                       ducking  under a pipe which has been
                                       welded to guard rails along a  walk-
                                       way between two baghouses.   This was
                                       necessary to prevent the guard rails
                                       from falling.  Despite the  "fix" the
                                       inspector  should place very  little
                                       faith in the security of these guard
                                       rails.

                                       The  bar across the walkway provides
                                       an  interesting hazard on  its  own.
                                       The  inspector who is preoccupied in
                                       conversation with plant personnel or
                                       in  looking at the baghouse  exhaust
                                       could easily flip over the  bar.  The
                                       location  of  the bar is  below  the
                                       center of gravity of most people.

     Looming  directly ahead of the falling inspector is a three foot  drop
in the catwalk.   The fall could result in (1) a fall over the catwalk, (2)
serious  eye injuries on the exposed ends of the grating,  and (3)  serious
head injuries.  Obviously, it is important to watch where you are  going and
to conduct the inspection at a controlled pace.
SLIDE 2-28
                                       This  is  a view of the  three  foot
                                       drop  off in the catwalk.   The  bar
                                       discussed  in the previous slide  is
                                       directly  above the field of view of
                                       this slide.

                                       This  is  not an  adequate  walkway.
                                       This  is the type of situation which
                                       should  be brought to the  attention
                                       of your supervisor before conducting
                                       the  inspection of the  baghouse  at
                                       the far end of this catwalk.
                                     20

-------
SLIDE 2-29
                                       At  the  other end  of  the  walkway
                                       shown  earlier,  it is necessary  to
                                       step  off  the catwalk to a  support
                                       beam, over some electrical conduits,
                                       to the next platform.   This is shown
                                       in  this slide and the one  directly
                                       below.

                                       Failure  to negotiate  this  obstacle
                                       course could result in a fall of  30
                                       feet.
SLIDE 2-30
                                       These   slides were  taken   simply   to
                                       show the types  of catwalks which  may
                                       be encountered,  especially in  some
                                       of the older facilities.   Inspectors
                                       should  not  attempt  to   use these.
                                       This is not adequate  and  safe access
                                       to the control  equipment.
                                     21

-------
SLIDE 2-31
                                       There  is a missing section of grate
                                       in this walkway.   The  unsuspecting
                                       inspector  could fall  approximately
                                       two  feet to the roof of a  baghouse
                                       directly  below  the  catwalk.   For
                                       those  who have been keeping  score,
                                       this  is the fourth major hazard  in
                                       the  40 foot run of this  particular
                                       walkway.
SLIDE 2-32
                                       Missing gratings or gaps in gratings
                                       can  occur anywhere in a plant.   In
                                       some cases,  the gratings were  ori-
                                       ginally  intended to protect  people
                                       from  entrapment in rotating  equip-
                                       ment such as the auger shown here.

                                       This  missing sections are  easy  to
                                       miss  if the plant is only dimly lit
                                       or  if  the inspector is  trying  to
                                       avoid  obstacles which are  overhead
                                       at the same time.   Plant  personnel
                                       often   rush  through  these   areas
                                       without   giving  the  hazards  much
                                       thought  because  they  have  become
                                       accustomed  to them.  The  inspector
                                       should  not feel obligated to  "keep
                                       up"  and  possibly incur  a  serious
                                       accident.
                                     22

-------
SLIDE 2-33
                                       This a picture of the floor around a
                                       packed bed wet scrubber.   The entire
                                       system is in a very dimly lit build-
                                       ing.  While walking between the bar-
                                       rels  and other stacked material  it
                                       would  be  easy to miss  the  raised
                                       section  of the floor shown in  this
                                       slide.  The severity of the accident
                                       would  depend on what was hit on the
                                       way down.

                                       Whenever  entering an internal  area
                                       from the outside,  it is prudent  to
                                       wait  for the eyes to adjust to  the
                                       low light conditions.
 SLIDE 2-34
                                        This   is   an  example  of  what  may   be
                                        lurking in those dimly  lit areas.
Source: National Audiovisuals Center
                                      23

-------
SLIDE 2-35
                                       This  is the pathway to a  large bag-
                                       house.   All  of the metal is  rust}
                                       and most of it is sharp.
SLIDE 2-36
                                       Around  many  small  baghouses,    the
                                       solids discharge valve is mounted at
                                       a  low spot close to the access  lad-
                                       der for the unit.   This is shown in
                                       the  adjacent  slide.    The  rotary
                                       valve shown here is just high enough
                                       that   it  may  not  be  seen while
                                       approaching the ladder.
                                       24

-------
SLIDE 2-37
                                       The   valve  stem  shown  in  this   slide
                                       sticks   out onto a  catwalk near  the
                                       top   of  a venturi scrubber.    It   is
                                       hard  to  see due  to  the lack  of  light
                                       in this  part of  the building.
SLIDE 2-38
                                       A  tie  down  stack for  an  ambient
                                       monitoring trailer is shown next  to
                                       the access ladder.   It is necessary
                                       to  go up the ladder to check on the
                                       Hi-Vol  collector.    While   coming
                                       down, it is easy to forget the stake
                                       and chain.

                                       Whenever  getting off any  ladder at
                                       the  top or the bottom, it is  useful
                                       to  pause  momentarily to check  for
                                       obstacles ahead.
                                      25

-------
 SLIDE  2-39
                                       This  is the same monitoring trailer
                                       shown in the last slide.  The recess
                                       shown  in  the slide is  a  favorite
                                       habitat  of wasps and  bees.   Other
                                       common  nesting  areas  include  the
                                       sheltered areas directly below roofs
                                       of baghouses and sheltered areas be-
                                       low  some  types of outdoor  control
                                       cabinets.  If you are hypersensitive
                                       to  wasps and bees,  you should  ask
                                       the  plant  personnel where  at  the
                                       plant they are usually found so that
                                       you  will not inadvertently  disturb
                                       the insects.
SLIDE 2-40
                                       While  walking around an air  pollu-
                                       tion  control device,  it is easy to
                                       forget  about rotating equipment  in
                                       the general area.   This slide shows
                                       a  partially covered fan sheave  and
                                       drive belt.   This was along a  very
                                       narrow  path to a venturi-rod scrub-
                                       ber.   It  is conceivable  (but  not
                                       easy)  for  loose  clothing  to  get
                                       caught  between the  rapidly  moving
                                       belt and sheave.  Occassionally, the
                                       entire belt guard will be missing.

                                       One  way to minimize the risk of en-
                                       trapment in rotating equipment is to
                                       avoid wearing loose fitting clothes.
                                       Ties should never be worn.
     The  area immediately around the rotating equipment should be  avoided
to  the extent possible.   If there is only one path to the control  system
and  there  is  a realistic risk of entrapment even when the  inspector  is
exercising caution, then the inspection should not be conducted.
                                     26

-------
SLIDE 2-41
                                       This  is a  winch beside  a  narrow  path
                                       to  the  same  system discussed  in   the
                                       last  slide.    It is 4 feet  above the
                                       surface and the cable  cuts over the
                                       path  that  must  be taken  by   the
                                       inspector.   The  operation  of   the
                                       winch is controlled by  plant  person-
                                       nel who cannot see the  scrubber  from
                                       their work station.   Resting one's
                                       hand  on  the winch or  simply being
                                       too  close when it starts  up could
                                       result  in  a  painful injury.

                                       It  should  be assumed that  equipment
                                       which is designed to move could  move
                                       without any  warning.
SLIDE 2-42
                                       It  is  often difficult to  find  an
                                       acceptable  location for making  the
                                       visible   emission  observation  for
                                       tall  stacks such as those found  at
                                       large utilities.    An inspector  may
                                       be  tempted  to climb the coal  pile
                                       for  this  purpose.   These  usually
                                       have   underground  coal   conveying
                                       equipment which makes standing on  a
                                       coal pile very dangerous.
                                    27

-------
SLIDE 2-43
                                       While  walking through the plant  or
                                       under control equipment,  inspectors
                                       must  be aware of overhead beams and
                                       other obstacles.  Without a hard hat
                                       it is possible to sustain a  serious
                                       head  injury  on these overhead  ob-
                                       stacles.   Hard hats should be  worn
                                       during  all plant inspections unless
                                       there  is a compeling safety  reason
                                       why  they  should not be worn  at  a
                                       specific plant.   Inspectors  should
                                       wear  hard hats even at plants which
                                       do not specifically require them  to
                                       be worn.
SLIDE 2-44
                                       Many  air pollution control  systems
                                       can be  reached only by climbing.  It
                                       is also necessary  to climb to almost
                                       all  sampling platforms.   The  next
                                       portion of the lecture concerns the
                                       proper  procedures  for climbing  lad-
                                       ders,   recognizing  safe and  unsafe
                                       ladders,    and    potential   ladder
                                       related accidents.
Source: National Audiovisuals Center
                                     28

-------
SLIDE 2-45
                                       This  illustrates a   common   problem
                                       with  ladders leading to  air   pollu-
                                       tion  control  systems.    Often   the
                                       first person up the  ladder (normally
                                       the plant  representative) deposits  a
                                       layer  of  mud and sludge  on the  foot
                                       rungs.   The  mud and sludge comes
                                       from the general conditions shown in
                                       previous slides such as 2-3 and  2-4.

                                       These  deposits can  make  the   ladder
                                       slippery.    It  is particularly im-
                                       portant to  climb the ladder care-
                                       fully  under  such  conditions.   If
                                       conditions  are  too  extreme,    the
                                       ladder  should not be used.
SLIDE 2-46
                                       This   illustrates   the WRONG way   to
                                       climb  a  ladder.   The inspector  has
                                       placed  his  hands on the side  rails
                                       of  the ladder  to avoid the mud which
                                       is  on the foot rungs.    He may not
                                       be  able to  support himself  if  his
                                       foot   slips  on one of the  slippery
                                       foot   rungs.   Only the  foot  rungs
                                       should  be   grabbed while  climbing,
                                       never  the side rails.  In many cases
                                       it  is necessary to have gloves  for
                                       climbing the ladders.
                                     29

-------
SLIDE 2-47
                                       This is the proper way to climb  the
                                       ladder.   The  inspector is  holding
                                       onto the the foot rungs.
SLIDE 2-48
                                       This   illustrates  another   common
                                       error made in climbing ladders.   The
                                       inspector  shown  in this  slide  is
                                       attempting  to  carry  the  portable
                                       instruments  in one of his hands (he
                                       is  also  holding  on  to  the  side
                                       rails).  Both hands must be free for
                                       holding on to the foot rungs.

                                       If  it is necessary to get the  por-
                                       table  instruments  to  an  elevated
                                       platform or control device,  a rope,
                                       side  pouch,  or  back pack  can  be
                                       used.   It  is  important  that   the
                                       pouch and/or back pack do not inter-
                                       fere with climbing by getting lodged
                                       in the ladder cage or other surroun-
                                       ding objects.
                                     30

-------
SLIDE 2-49
                                       This slide illustrates climbing with
                                       the  side  pouch.    Note  that  both
                                       hands  are now free for climbing.

                                       The  dangling dial type  thermometer
                                       near the back of the pouch could get
                                       caught of a portion of the cage (not
                                       shown).   Instruments  which are  as
                                       long  as the dial  type  thermometer
                                       should  not  be carried in the  side
                                       pouch.
     A  bucket  with  a rope can be used to  transport  large  instruments,
cables,  and any other bulky items.  Obviously it is important that nothing
falls from the bucket.   The rope and bucket should not be used near  power
lines or when the wind speed is high.
SLIDE 2-50
                                       The  last  two slides have shown  an
                                       inspector  with gloves climbing  the
                                       ladder.   This slide shows a  common
                                       type  of  slip resistant foot  rung.
                                       It  is very helpful to  have  gloves
                                       when climbing this type of ladder.
                                       31

-------
SLIDE 2-51
                                       This slide shows the same ladder  as
                                       the  previous slide.   The inspector
                                       is  attempting to climb  the  ladder
                                       without gloves.   To avoid pain,  he
                                       is hooking his wrist around the back
                                       of the foot rung.   He obviously has
                                       only  a  very poor grip of the  foot
                                       rung and he could easily fall.  This
                                       should never be done.
SLIDE 2-52
                                       This  is a view down a 30 foot  lad-
                                       der from a baghouse.   It is readily
                                       apparent  that  the foot  rungs  are
                                       both  rusty and have some very sharp
                                       edges.   Gloves  and caution  are  a
                                       necessity  when climbing a ladder of
                                       this type.   It may be advisable  to
                                       find  another means of access or  to
                                       delay  inspection of the  particular
                                       unit  until there is a better ladder
                                       available.
                                     32

-------
SLIDE 2-53
                                       In  evaluating whether or not a lad-
                                       der is safe,   there are a number  of
                                       different factors which must be con-
                                       sidered.   As  shown in this  slide,
                                       the  fixed ladder with cage must ex-
                                       tend  at  least 3.5 feet  above  the
                                       surface of the roof or elevated cat-
                                       walk.
 Source: National Audiovisuals Center
 SLIDE  2-54
                                       The  ladder must be at least 18  in-
                                       ches wide.   Generally the width  of
                                       the  rung  meets the criteria  shown
                                       here,   however,  the  cage  can  be
                                       damaged.   This can restrict  access
                                       at  the point that the cage is  bent
                                       inward  and can make the ladder very
                                       dangerous if the inspector is climb-
                                       ing with a side pouch or back pack.
Source: National Audiovisuals  Center
                                      33

-------
SLIDE 2-55
                                       There  should be 8 inches  clearance
                                       between  the foot rungs and any back
                                       wall.   This is necessary to  ensure
                                       that  the  foot rests  securely  and
                                       completely  on the foot  rung.   The
                                       person  shown  in this slide  should
                                       have  been climbing by  placing  the
                                       back  of  the heel against the  foot
                                       rung.

                                       While the large majority of  ladders
                                       on  control  systems initially  have
                                       the necessary foot clearance,   it is
                                       fairly  common  to  have  electrical
                                       conduits or obstacles at one part of
                                       the  ladder.   This can result in  a
                                       misstep and fall.

     Occassionally,   there may be a support beam passing across the back of
the ladder closer than 8 inches.    While climbing the ladder,  it is useful
to watch out for these beams, conduits or other potential problems.
SLIDE 2-56
                                       The  foot  rungs  should  be  evenly
                                       spaced to prevent missteps and falls
                                       from the ladder.   This slide  shows
                                       the poor mating of a small extension
                                       section  to  the bottom of  a  large
                                       ladder  going  to a small  baghouse.
                                       The  gap between the two ladders  is
                                       different than the distance  between
                                       the foot rungs of either ladder.  An
                                       accident is most likely while coming
                                       DOWN  from the baghouse since it  is
                                       easy  to forget that the ladder  has
                                       been  "pieced"  and you  cannot  see
                                       it coming.
                                     34

-------
SLIDE 2-57
                                       Ladders  are  supposed  have  some   type
                                       of   secure guard  to prevent   someone
                                       from  inadvertently walking  into the
                                       open area  at the  top  of  the   ladder.
                                       This  slide  illustrates  a  very   good
                                       type of  guard which will close  auto-
                                       matically  when leaving the ladder.
SLIDE 2-58
                                       This slide shows the top portion  of
                                       a  caged ladder which does not  have
                                       any restraint at the point of entry.
                                       The  chain which was formerly across
                                       the entrance of the ladder has  been
                                       removed.

                                       Accidents  can  occur at spots  like
                                       this   when  the  inspector  becomes
                                       preoccupied  in  conversation   with
                                       plant   personnel  or  is  too  busy
                                       looking at components of the control
                                       system.  This is another reason that
                                       the inspection must be conducted  at
                                       a controlled pace.
                                      35

-------
SLIDE 2-59
                                       This  slides illustrates an  uncaged
                                       ladder  with a permanent angle  iron
                                       across the entry point to the ladder
                                       top.   To climb down from the fabric
                                       filter  shown in this slide,   it  is
                                       necessary  to duck under the  bar and
                                       then  attempt to keep your  feet  on
                                       one of the foot rungs.   This is not
                                       an  adequate  access  ladder.    The
                                       angle  iron should be replaced  with
                                       one of the types of restraints shown
                                       in the last two slides.
SLIDE 2-60
                                       This  is the top of a AO foot ladder
                                       leading to a set of small baghouses.
                                       Approximately 6 inches above the top
                                       of  the ladder is a large  lamp.   A
                                       tired or unaware inspector could hit
                                       either  the lamp itself or  the  its
                                       sharp  reflector.   The result could
                                       be a head injury, a fall, or both.
                                      36

-------
SLIDE 2-61
 t
This  is  a ladder leading  from  an
internal  catwalk  to a  roof  where
there are several baghouses.   There
is very little clearance between the
sloping  roof  and the edge  of  the
siding  directly above  the  ladder.
To  complicate matters further,  the
solids on the sloping roof are  very
slippery.   While  trying to concen-
trate on one problem,  an  inspector
could easily forget about the other.
SLIDE 2-62
                                       Sometimes  it is not the ladder that
                                       is dangerous,  but the general  con-
                                       ditions near the ladder.  This slide
                                       shows  a ladder leading up to a  wet
                                       scrubber  on a cupola.   During  the
                                       short  periods  when slag  is  being
                                       skimmed,  the  area surrounding  the
                                       ladder  is enveloped with a dramatic
                                       display of sparklers.
                                      37

-------
SLIDE 2-63

                                       This  is  a slide of another  access
                                       ladder  leading to a cupola  scrubber.
                                       The plant personnel are in the  pro-
                                       cess  of "dropping  bottom".   While
                                       plant  personnel  are usually  quite
                                       careful in this situation,  they may
                                       be  unaware that an inspector is  in
                                       the  area.   The burst of fire  that
                                       results   from   "dropping   bottom"
                                       develops  in a fraction of a  second
                                       once the bottom support is withdrawn
                                       from  the  cupola.   A  person  just
                                       coming  down  the  ladder  from  the
                                       scrubber  would  be  very  seriously
                                       burned.   It is necessary to be con-
                                       stantly  aware  of  the   operations
                                       under  way  at the plant during  the
                                       inspection.
SLIDE 2-64

                                       This is an entry way from a roof  to
                                       a  ladder leading down to the  plant
                                       floor.   Very  high humidity results
                                       in  a  steaming effect as  the  cold
                                       ambient air enters the  warm,  humid
                                       air.   A  cloud of steam is apparent
                                       on  the  left portion of  the  entry
                                       way.   Upon entering this area,  any
                                       inspector  wearing glasses will  not
                                       be able to see.  The steam can be so
                                       heavy  at  times  that  even   those
                                       without  glasses  can not  see  more
                                       than  a  foot ahead.   Several  feet
                                       into the enclosure is an opening for
                                       the ladder.   There is no  restraint
                                       or  other protective device to  pre-
                                       vent the temporarily blinded inspec-
                                       tor  from  taking a 30  foot  plunge
                                       through  the  opening  down  to  the
                                       operating floor.

    Any steam filled area deserves special precautions.  The inspector must
slow down until it is possible to see all obstacles, openings in the floor,
and other hazards.   Extremely low visibility caused by steam is one of the
most  common conditions encountered in inspection of air pollution  control
equipment.
                                     38

-------
SLIDE 2-65
                                       Portable  ladders  can present   some
                                       special  problems for the  inspector.
                                       Before using these ladders,   several
                                       basic safety checks are needed.
 Source: National Audiovisuals Center
SLIDE 2-66
                                       Makeshift  ladders  such as the  one
                                       shown  in this slide should  not  be
                                       used under any circumstances.  If it
                                       has  been necessary to "fix" one  of
                                       the rungs,  it is possible that some
                                       of the others have also weakened.

                                       All  of the foot rungs should be in-
                                       spected  before use of  the  ladder.
                                       If  any of these appear to rotted or
                                       the  rungs are separating  from  the
                                       side rails, the ladder should not be
                                       used.
  Source: National Audiovisuals Center

-------
SLIDE 2-67
                                       One  of the basic requirements of  a
                                       portable  ladder is that it must  be
                                       secure  at the bottom.   It is often
                                       difficult  to find a  location  near
                                       air   pollution  control   equipment
                                       where there is no sludge or mud.

                                       This slide shows a ladder sitting in
                                       a slippery layer of sludge next to a
                                       venturi scrubber.  There is a possi-
                                       bility that anyone using this ladder
                                       would fall.

     In addition to locating a dry spot for the ladder,  it is necessary to
have  the right type of slip resistant protector on the bottom of the  lad-
der.  Two of the most common slip protectors are spurs and pads.
SLIDE 2-68
                                       This is the same ladder shown in the
                                       previous slide.   Another common pro-
                                       blem with portable ladders  involves
                                       resting them against a support which
                                       is  weak.   Close examination of the
                                       slide  illustrates  that  the  small
                                       angle iron which is supporting  this
                                       ladder  has  been cut  approximately
                                       80%  of the way  through.   The  load
                                       created as the inspector climbs  the
                                       ladder  will be  enough to cause  the
                                       angle iron to break.
                                      40

-------
  SLIDE 2-69
                                         When  using any portable ladder,   it
                                         should be sloped so that the  length
                                         from the wall is one fourth the lad-
                                         der height.   This is illustrated in
                                         this slide.
Source: National Audiovisuals Center
  SLIDE 2-70
                                         The  portable  ladder should  extend
                                         three feet above the roof.   This is
                                         illustrated in the adjacent slide.
   Source:  National Audiovisuals  Center
                                        41

-------
  SLIDE  2-71
                                        The  ladder  should never go  to  or
                                        near  the vicinity of  power  lines.
                                        If this is the only way to reach the
                                        air   pollution  control  equipment,
                                        then  the inspection should  not  be
                                        conducted at the present time.
Source: National Audiovisuals Center
 SLIDE  2-72
                                        When  climbing any  fixed or portable
                                        ladder, only one person should be on
                                        the  ladder at a  time.   The  first
                                        person  going  up the  ladder  could
                                        drop some  tools or  equipment on  the
                                        person climbing directly below.  The
                                        first  person  could also  fall  and
                                        thereby injure the  second.  While it
                                        takes  more  time to wait  for  each
                                        person  to reach the top of the lad-
                                        der,  this is the  only safe way  to
                                        climb.
  Source: National Audiovisuals Center
                                      42

-------
SLIDE 2-73
                                       The   basic personal  protective  items
                                       necessary  for  walking  and   climbing
                                       are   shown in  this   slide.     These
                                       should   be worn by inspectors during
                                       all   inspections unless there   is   a
                                       compeling  safety reason why   these
                                       should   not  be used at a   specific
                                       plant.
SLIDE 2-74

                                       Safety shoes have several main func-
                                       tions.  They protect against falling
                                       objects which could injure the toes.
                                       The  types of activities where  this
                                       type  of accident is likely are  not
                                       those  performed  by most field  in-
                                       spectors.   The most important func-
                                       tion  of safety shoes,  for  inspec-
                                       tors,  is the slip resistant  soles.
                                       This  minimizes the risk of falls on
                                       all slippery areas around the equip-
                                       ment  and  on the various  types  of
                                       elevated  surfaces commonly  encoun-
                                       tered by inspectors.

     The purpose of this slide is to illustrate that these shoes will  wear
out  and become less useful for preventing falls.   They should be replaced
when they reach this stage.

     The type of safety shoe must be appropriate for the type of  chemicals
and  conditions which will be encountered.   The primary considerations are
(1) the extent to which chemicals could penetrate the sole of the shoe  and
the  skin and (2) the potential consequences of static build-up.   If there
is the possibility for static electrical detonation of flammable vapors  it
may be necessary to use a shoe designed to dissipate the static.

                                      43

-------
SLIDE 2-75
                                       Hard  hats  should  be  cleaned  and
                                       inspected at the least on a  monthly
                                       basis.   The  suspension  should  be
                                       checked  to  ensure  that  it  still
                                       meets  the originial  specification.
                                       If  there  are any cracks  or  other
                                       problems with the hat,  it should be
                                       discarded and a new one obtained.
                                      44

-------
SLIDE 3-1
       HAZARDS TO VISION
The eye is one  of  the most vulnerable
parts of  the body to industrial ha-
zards.  This  is because it  does not
heal as  quickly or  as well  as other
organs.  The  cornea, lens, and humors
have very  few blood  vessels  (so that
they are clear) which results in slow-
er healing.   The nerves  of the retina
cannot regenerate, so damage to these
is permanent.
       3-2
             EYE INJURIES

                 MINOR
   Presence of foreign body
   Abrasion from rubbing
   Irritation from fumes
   Orbital margin bruise
                 MAJOR
   Perforation of eye by particles
   Thermal Bums
   Chemical bums from fumes or splashes
   Disruption by Impact
Industrial eye injuries can range
from temporary  to  permanent.    Exam-
ples of  some  common major and  minor
eye  Injuries are shown in  this  slide.
The  major  injuries  often  result  in
partial  or  permanent blindness.   It
is probably easy  for every inspector
to imagine  plant  situations  that  he
or she encounters on a  regular basis
that could result in injuries of each
of these types.
                                          45

-------
SLIDE  3-3
                                        This  slide   shows  a  fairly  common
                                        plant situation;  this  baghouse  ex-
                                        haust vent  is directed  down  at  the
                                        platform around  the  baghouse.   Under
                                        normal conditions this is not a prob-
                                        lem, however,  in the  case  of a  bag
                                        failure, etc.  particulate  could  be
                                        flung at the inspector at the exhaust
                                        gas velocity of  3,000 fpra.
SLIDE 3-4
                                        Grinding operations  such as  the  one
                                        shown here or those found at foundries
                                        and in other metal fabrication indus-
                                        tries are  a  common  source  of flying
                                        particles.  Particles that get in the
                                        eye can  easily  scratch  the eyeball,
                                        and more  seriously,  those  traveling
                                        very fast  can perforate the  eyeball
                                        and cause  internal damage,  sometimes
                                        without even being felt.
Source: National Audiovisuals Center
                                        46

-------
SLIDE 3-5
                                        This is a photograph of a valve on the
                                        discharge line of a wet scrubber pump.
                                        The liquor is  under approximately 90
                                        psi and the pH is quite high.  If care
                                        is not taken in  sampling  the  liquor,
                                        it can easily splash into unprotected
                                        eyes.  Thus, the valve must be opened
                                        gradually, the receiving container
                                        must not  be  prone  to  splashing,  and
                                        the inspector should be wearing splasl
                                        goggles.
 SLIDE 3-6
                                        The  fumes or vapors of some chemicals
                                        can  irritate  or  actually  burn  the
                                        eyes.   Chemical splash goggles (which
                                        will be shown later) should always be
                                        worn around  open vats  and  tanks of
                                        potentially harmful chemicals such as
                                        those  shown in this slide.
Source: National Audiovisuals Center
                                        47

-------
 SLIDE 3-7
                                         This is  a  view  inside  a  traveling
                                         grate of  a   municipal   incinerator.
                                         Occassionally an aerosol can explodes
                                         as the  material  charged  to the  in-
                                         cinerator heats up.  The  metal  frag-
                                         ments from  the  can pose  a  hazard  to
                                         anyone  looking   directly  into  the
                                         hatch, thus, it is wise  to  look into
                                         these hatches with caution.   The eyes
                                         should never be in the possible direct
                                         line of  flight  of exiting  fragments
                                         and eye  protection  should  always  be
                                         worn.

                                         In the case  where the material inside
                                         a hatch is very hot and bright,  a ra-
                                         diation shield may also  be  necessary
                                         to prevent thermal or other  radiation
                                         damage to the eye.
 SLIDE 3-8
                                         Although not likely in the case shown,
                                         sparking can possibly cause eye inju-
                                         ry in either of  two  ways:   (1)  burns
                                         from sparks reaching  the  eye or  (2)
                                         damage from glare  or  U.V.  radiation.
Source: National Audiovisuals Center
                                        48

-------
    CATEGORIES OF EYE HAZARDS
• Physical
• Chemical
• Thermal Radiation
• Other Radiation
SLIDE 3-9
                                        Eye  hazards, Including   those   just
                                        shown, can be grouped into four cate-
                                        gories.  Physical   hazards   include
                                        blows such as  from walking  into  low
                                        hanging equipment  or beams,  lacera-
                                        tions from  sharp  edges  moving  past
                                        the eye, and the introduction of for-
                                        eign bodies flying particles.

                                        Chemical hazards include splashes
                                        from opening valves or containers un-
                                        der pressure or  being near open pro-
                                        cess vats and tanks  or  irritating or
                                        burning fumes and vapors such as sty-
                                        rene or butanol.

                                        Thermal eye  hazards  include  the  di-
                                        rect viewing of high temperature
                                        operations.  Fortunately, excessive
                                        heat usually causes the eye to close,
                                        however, this results in burns to the
                                        eyelid.

     Other radiation hazards include U.V.  light from welding and cutting op-
erations, intense  visible  light  from  lasers,  infrared,  and  microwaves.
SLIDE 3-10
                                        This- slide shows three  types   of eye
                                        protection of general use  to  the air
                                        pollution control inspector.  They
                                        are (from  top  to  bottom)  chemical
                                        splash goggles,  safety  glasses with
                                        side shields (to protect against fly-
                                        ing objects),  and  visitor  glasses.

                                        Most industrial facilities require
                                        eye protection and  inspectors  should
                                        be sure  that theirs  satisfies plant
                                        requirements.  It  is suggested  that
                                        inspectors use eye protection even if
                                        not specifically  required.   At  the
                                        very least, it will  prevent  the intro-
                                        duction of chemicals and foreign bod-
                                        ies into the eye by careless rubbing.
                                      49

-------
SLIDE 3-11
                                        Unlike this  example, visitors  specs
                                        or glasses should not have many
                                        scratches.  If  they do,  a new  pair
                                        should be  used and  the  others  dis-
                                        carded.  When  doing  much  field work,
                                        it is preferable to  have prescription
                                        or nonprescription safety glasses with
                                        side shields.   These are  less prone
                                        to scratching  and  all  better peri-
                                        pheral vision.

                                        Splash goggles should be worn whenev-
                                        er there  is  the chance  of splashing
                                        chemicals or  irritating  fumes.   Im-
                                        pact goggles  can as  a  substitute for
                                        safety glasses.  Radiation shields
                                        must be  used  when  there is danger of
                                        thermal or other radiation.
     In the event that  chemicals  do get  introduced  into the eye, immediate
treatment is essential.   The  eye should  be flushed with as much water as pos-
sible using an eyewash station, if  convenient,  or any  other source of clean
water.  If the  individual  is wearing contact  lenses,  they  must  be removed
first.
     ON INDUSTRIAL JOBS . .  .
               DON'T
     WEAR CONTACT LENSES
SLIDE 3-12

                                        This  statement  is  from  a  National
                                        Safety Council  slide  series on  eye
                                        safety.   We  also  strongly  recommend
                                        not wearing  contact lenses  while at
                                        an industrial  plant.   Many  chemical
                                        plants,  in fact, do not allow employ-
                                        ees or  visitors to wear  contacts in
                                        the production  areas.

                                        There is  an OSHA  standard   [1910.134
                                        (e) (5)  (ii)]  which strictly forbids
                                        the wearing of  contact lenses in con-
                                        taminated atmospheres  with  a  respi-
                                        rator.

     Hard contacts can increase the damage done to the  eye by a  foreign body
which gets  trapped  behind  it.   Soft  contact  lenses,  particularly  the  gas
permeable ones, may make  the  eye  more susceptible  to  chemical damage.   Some
chemicals such as acetone may also cause soft contacts  to opacify.

     However, to this date the National Society  for the Prevention  of blind-
ness has no contact-caused  injuries  on record  as long  as goggles appropriate
for the situation are worn.   They have  thus  just issued a position statement
on the wearing of  contact  lenses in the  industrial environment  which cautions,
but does not preclude the use of contact lenses.  This  statement is quoted in
full on the following page.
                                      50

-------
      "Contact lenses may be worn in many occupations.   Contact  lenses  provide
 an adequate means of visual rehabilitation for employees who have had a  cat-
 aract removed from one or both eyes; who are  highly  near-sighted, or who  have
 irregular astigmatism from  corneal  scars or  keratoconus.  However, when  the
 work environment entails exposure to chemical fumes, vapor, or  splashes,  in-
 tense heat, molten metals, or highly particulate  atmosphere, contact lens use
 should be  restricted.   Certain federal or state regulations  may also limit
 their use.*

      Contact lenses, of themselves, do not provide eye protection in the  in-
 dustrial sense.  For occupational use, contact lenses should be worn  only in
 conjunction with appropriate industrial eye protection.**

      The employer should ensure the  identification of the contact lense wearer
 for appropriate emergency care  and  for protection in work  areas hazardous to
 the eyes."


*Wearing of  contact lenses  in  contaminated  environments  with  a respirator
 shall not  be allowed.   Federal Register, Volume  36,  Number  105,  Part  II
 #1910, 134 (e)(5)(ii).
*To be of  industrial quality,  safety eyewear  devices must meet  or exceed  all
 the requirements of the  "American National Standard Practice for Occupation-
 al and Educational Eye and  Face Protection,  Z87.1, 1979",  or later revisions
 thereof, as  published by  the American  National Standards  Institute,   Inc.
                                         51

-------
  SLIDE 3-13
     HAZARDS TO HEARING
                            There   are  two types of noise  expo-
                            sure:   chronic and acute.   Field in-
                            spectors are rarely subjected to the
                            chronic exposures.

                            However,  the short, acute exposures
                            do  add up  and there is always  the
                            possibility  of a temporary hearing
                            loss  even  after a short term  expo-
                            sure.    Consequently, the  agency in-
                            spector  must be aware of   potential
                            noise  sources,  the consequences  of
                            noise   exposure,  and the  methods of
                            hearing protection.
  SLIDE 3-14
                        SEMICIRCULAR
                          CANALS
                                EIOHTH NERVE
                               OVAL WINDOW
External Ear
Middle
 Ear
An intense, sudden noise (such as an
explosion)  can severly  damage  the
middle  and inner ear and can result
in hearing loss.   But the type  of
hearing loss associated with indus-
try  is from much lower noise levels
over a prolonged period.   This type
of  hearing loss results because the
hair  cells lining the  cochlea  are
gradually  destroyed by overstimula-
tion.   These  hair cells  transform
the  vibration in the liquid of  the
ear into nerve impulses.   Once des-
troyed, they do not regenerate.
       The early stages of this type of hearing loss result in an increase in
  the hearing threshold only at the higher audible frequencies so it is often
  not noticed.   At first,  the individual does not realize that he or she is
  progressively  losing  hearing  ability.   Some temporary hearing  loss  or
  ringing (ITS,  Temporary Threshold Shift) does result in permanent  hearing
  damage.
                                        52

-------
SLIDE 3-15
                                       This   slide   shows  an  example   of   a
                                       source  of  impact noise,   one  of the
                                       types   of noise  that can   cause ear
                                       damage.  These magnetic impulse gra-
                                       vity   impact   (MIGI) rappers on the
                                       ESP roof are  commonly  encountered  by
                                       agency inspectors.
                                       This  is  a fan on a baghouse  of  a
                                       asphalt  plant kiln.   Areas  around
                                       the  large fans of  control  systems
                                       tend to be noisy.
                                      53

-------
 SLIDE 3-17
                                         This is a ball mill at a  plant which
                                         grinds clinker.   THe noise  level in
                                         the  area surrounding the ball  mill
                                         was  high  enough  that one   had  to
                                         shout to communicate; this is always
                                         a   good  indication  that   it   is
                                         appropriate to wear ear protection.
 SLIDE 3-18
       MAJOR FACTORS WHICH
   CHARACTERIZE NOISE EXPOSURE
• Overall Noise Level
• Composition of Noise
• Duration and Distribution of Exposure During the Work
 Day
• Total Time of Exposure During Worklife
This  slide  lists  the four  factors
which  characterize  noise  exposure
and which effect hearing loss.   Over
the same time period,  the higher the
noise level in  dB,   the greater  the
exposure.   Composition of the  noise
also has an effect,  single frequency
noise  is more  damaging than broad-
band   noise.    The   exposure   is
cumulative  so  that the total   time
over   a  lifetime    is   important.
However, it is  not  strictly additive
and    consequently   duration    and
distribution must be considered.

-------
     SLIDE 3-19
          MAXIMUM
          EXPOSURE
    PltESSURE  PER DAT
     M/m'    <«A
                                 INDICATORS
                                 OF LEVEL
    CHIPPER (US Ml
             no
"""""•
   CUANEI.
**»•<»» WHIWM
110 —

00

•0 —

M

70 —

10

BO —

1C

so —

H

10 —

 .
to
     15 MIN
     50 MIN
     I HOUR
2     t HOURS

     • HOURS
                              VWCC COMMUNICATION IMPOS
                              VOICC COMMUNICATION DIFFICULT
                              SHOUT AT 09 FOOT
                              NORMAL VOICE AT. 0.8 FOOT

                              NORMAL VOICE AT 1,5 FEET
                  00001
                  oooooz
This  scale was  constructed to  give
an  idea of how  the levels  of  some
familiar  noise   sources related  to
the   OSHA  specified  maximum   ex-
posures.   At  the present  time,  90
dBA*  is the maximum noise level  to
which  most  worker can  be  exposed
with  a reasonable expectation of no
hearing damage.    The information in
the column on  the right can be  used
to  roughly estimated noise  levels.
As  a rule of  thumb,   ear protection
should  always be used  when  normal
speech  can  not be understood at  a
distance of 2  to 3 feet.  (*The  dBA
noise  level   scale is weighted  for
frequencies in the hearing range.)
     SLIDE 3-20

                                             There are a number of options avail-
                                             able  in  choosing  ear   protection.
                                             Pictured   here  are  premolded  ear
                                             plugs,  moldable  ear  plugs,  canal
                                             caps,  and ear muffs.    Not pictured
                                             are  the less commonly   used  custom
                                             molded ear plugs.  Each  have advant-
                                             ages  and disadvantages  with  repect
                                             to comfort,  and convenience in var-
                                             ious situations.   For example,  ear
                                             plugs  are easy to carry but  incon-
                                             venient to put in quickly.

          Ear  muffs and canal caps  are very easy to put on and  take  off,  but
     they  cannot  be stored in a pocket and are much less comfortable  than  ear
     plugs to wear for extended periods.

          The  inspector should always  carry his or her own ear  protection  and
     should wear it as prescribed by the plant.   Continuous wear is recommended
     in   a  moderately  noisy plant;  after a short period  of  acclimation  ear
     protection actually aids communication.   In addition, it is not good to be
     removing and reinserting ear plugs with soiled hands as one moves  about the
     plant.
                                           55

-------
SLIDE 3-21
         Ear
        Protector
 Bangs of
Attenuation
        Cotton
        Ear Plug
        Ear Muff
       Muff & Plug
5 to 2MB
15 to 35dB
15to45dB
28to48dB
Different  types  of  ear   protection
differ in the amount  of   attenuation
or  reduction  of noise   level  that
they provide.   This  slide shows the
reanges   of  attenuation  for  four
forms of ear  protection.   Attenua-
tion  is given as a range because it
differs at different  frequencies.

The cotton is not a recommended form
protection and is shown for compari-
son  purposes.   The  attenuation  of
properly  fitted  ear plugs and  ear
muffs is nearly equivalent.   A com-
bination  of  the  two can  provide
additional protection.  Probably the
most  important factors for the  in-
spector to consider when  selecting a
type of ear protection are (1) noise
levels, (2) proper fit (3)  reason-
able  comfort,  and (4) convenience.
If ear protection is  comfortable and
convenient, it will usually be used.
                                     56

-------
SLIDE 4-1
                                       Electrical hazards,   explosions  and
                                       burns are discussed  in this lecture.
                                       Since  gas temperatures between  200
                                       and 1800 °F are common in air pollu-
                                       tion control equipment,  there are a
                                       number  of ways for  a burn to  occur
                                       in  the  vicinity of the  collector.
                                       Burns  can also occur due  to  steam
                                       from process equipment.

                                       Explosions can occur when there  are
                                       (1)  deposits of solids or (2) flam-
                                       mable liquids being   handled.   Both
                                       of  these  situations  occur  during
                                       inspections.

     Electrical shocks can occur due to improperly grounded equipment,  im-
properly grounded probes,   exposed wiring, high voltage tracks, and opening
of electrical cabinets.
SLIDE 4-2
                                       This slide shows flames engulfing an
                                       access ladder to a cupola wet  scrub-
                                       ber  system.    This occurs when  the
                                       plant is "dropping bottom".  The in-
                                       spector  should  not   go  near  the
                                       scrubber  system  when  this   is  to
                                       occur.

                                       Plant  personnel  are  usually   quite
                                       careful  about  advising  inspectors
                                       about  this operation.   The problem
                                       could occur when the cupola operator
                                       is   unaware of the presence  of  the
                                       inspector.    The  inspector must  be
                                       aware of process operations and must
                                       not  assume that the operators  will
                                       realize that  he or she is present.
                                    57

-------
 SLIDE 4-3
                                       This  is  a  view of a  wet  scrubber
                                       system  on another cupola.   The gas
                                       leaving the  top of the cupola is  at
                                       temperatures  varying  from 1800  to
                                       2200  °F.    There is a small  quench
                                       chamber  adjacent to the  cupola  to
                                       reduce  the  gas temperature to  the
                                       300 to 400 °F.  The gas then travels
                                       down the inclined duct to a  venturi
                                       rod scrubber.   The next slide shows
                                       a  close-up  view of the gas duct  at
                                       the inlet of the scrubber.
SLIDE 4-4
                                       The  gas duct shown in the  previous
                                       slide  is  at the very top  of  this
                                       slide.   The main liquor inlet is on
                                       the  left side of the scrubber inlet
                                       (near the center of the slide).  The
                                       discolored area just below the  main
                                       liquor  inlet  shows  that  the  gas
                                       temperature  at  this point  can  be
                                       quite  high.   Leaning against  this
                                       portion of the scrubber could result
                                       in a painful burn.  This part of the
                                       unit  is within easy reach of anyone
                                       walking around the unit.
     It is very common to find uninsulated ducts near air pollution control
equipment  that are between 200 and 800 °F .   Touching the duct walls  can
occur  as the inspector is (1) trying to move around the various  obstacles
around  the  collector or (2) attempting to use a measurement port  on  the
duct wall.  To minimize the risk of burns, it is necessary to be constantly
aware of which ducts are at elevated temperature.
                                     58

-------
SLIDE 4-5
                                       A  row of  4  inch   diameter  sampling
                                       ports   are shown  here.   Most people
                                       are careful  initially and use gloves
                                       to remove  the  plugs.   When  prepar-
                                       ing to leave,  they often forget  that
                                       the plugs  can stay very hot for  a
                                       long  time.    Picking up  the  plugs
                                       with  an unprotected hand results in
                                       a burn.

                                       Another  cause of burns is the grab-
                                       bing  of the probe as it leaves  the
                                       stack   or  duct.    If gloves are  not
                                       used a burn  will  result from the 200
                                       to 1000  °F probe.   As in the case of
                                       the plugs,  it takes some time  for
                                       the probes to  cool off.   The larger
                                       the probe,  the  longer it takes  to
                                       reach  a  safe temperature.    Most
                                       problems  occur because of hot pitot
                                       tubes.
SLIDE 4-6
~v*"w**^
                                       This   is the pneumatic solids  hand-
                                       ling   system  for a large  hot  side
                                       electrostatic   precipitator.    The
                                       solid   material  in  the  transport
                                       pipes  can have temperatures  ranging
                                       from   300  to  500  °F.   Obviously,
                                       these   pipes  should not be  touched
                                       while   walking  around  the   hopper
                                       area.   Since they are mounted close
                                       to  the gratings it is easy to brush
                                       up against them by accident.
                                   59

-------
SLIDE 4-7
                                       This  is the uninsulated roof  of  a
                                       pulse  jet collector on an asphaltic
                                       concrete plant.  The gas temperature
                                       directly below these access  hatches
                                       is normally 325 °F.  One sign of the
                                       elevated  gas  temperatures  is  the
                                       loss of paint on the access hatches.

                                       Burns  can  occur while standing  on
                                       the  roof or when reaching  down  to
                                       remove  the  access hatch to one  of
                                       the compartments.

     This  slide shows a relatively mild case of a very  common  situation.
It is typical for the roofs of some collectors (or process equipment in the
area  of the collector) to be at 400 to 600 °F.   When climbing up to  this
area,  people  tend to place their hands on the flat surface as they  reach
the  top of the ladder.   In some cases,  the plant personnel walk across a
hot area (e.g.,  top of boiler near the steam drum) to reach the air pollu-
tion control system or the measurement ports.    Such shortcuts are never a
good idea.
SLIDE 4-8
                                       Very serious burns can occur due  to
                                       steam.   In some processes, very hot
                                       steam is released intermittently. If
                                       the  inspector happens to be  on  an
                                       elevated  walkway  or other  exposed
                                       area, a serious accident can occur.

                                       In power stations,  a high  pressure
                                       steam  leak  can pose a  significant
                                       risk.  THESE LEAKS CANNOT BE SEEN OR
                                       HEARD.   THERE  WILL BE NO  APPARENT
                                       CLOUD OF CONDENSED STEAM IN THE AREA
                                       OF THE LEAK.   When the plant  alarm
                                       indicates   a  high  pressure  steam
                                       leak,  the inspector should not move
                                       around the boiler area.   If outside
                                       when the alarm sounds, the inspector
                                       should not enter the boiler area.
     The  potential for steam burns is one of the reasons that it is impor-
tant  for plant personnel to accompany an inspector at  all  times.   Plant
representatives  are familar with the intermittent operations which  result
in  a  steam cloud and they generally know the protected  locations.   They
also  know  the procedures to be followed in the event of a  high  pressure
steam leak.
                                    60

-------
SLIDE 4-9
                                       This  is the access hatch for  a hop-
                                       per  on a baghouse.   The solids  in
                                       the  hopper   are  at 300°F  and  will
                                       flow  like water  when  the  hatch  is
                                       opened.   Serious burns can occur  to
                                       anyone  in the  immediate vicinity  of
                                       the hatch when  it is  opened.    This
                                       problem  is  easily avoided since the
                                       inspector has  no  business   being
                                       close to a hatch  being opened.
SLIDE 4-10
                                       This  is  part  of  a   chemical   plant
                                       handling  large quantities  of   acid.
                                       Chemical  burns can  occur from  leaks
                                       or   sprays  of  acid.   If  a burning
                                       sensation  is felt on the   head,   do
                                       not  look up!    Leave the   immediate
                                       area before attempting to locate  the
                                       source of the acid.

                                       It   is  an instinctive response   to
                                       look up when a  burning sensation   is
                                       felt on the head.  If it is due to a
                                       small leak above the inspector,   the
                                       acid may enter  the eye.
                                    61

-------
SLIDE 4-11
     In
(GFIs),
                                       This  is  a view of the roof  of  an
                                       ambient monitoring station.  The Hi-
                                       Vol  is directly above the field  of
                                       view  of the slide.   The power line
                                       for  the Hi-Vol motor is lying in  a
                                       puddle  of water on the  roof.  This
                                       situation  could result in  a  fatal
                                       shock  because the person  servicing
                                       the  unit  would be standing in  the
                                       puddle with the power line in it.

                                       All Hi-Vols should be equipped  with
                                       ground  fault interrupters.   When a
                                       short  circuit is sensed these  shut
                                       down the power in just a few  milli-
                                       seconds,  before  a fatal shock  can
                                       occur.
addition  to equipping the Hi-Vols with ground fault  interrupters
the  power line should be removed from the puddle of water.
SLIDE 4-12

                                       This  is the electrical box for  the
                                       motor  operating a rotary  discharge
                                       valve on a small baghouse.   The box
                                       cover has been partially removed and
                                       the hot line is exposed.

                                       Most  people  would not stick  their
                                       hand into an electrical box, however
                                       in this case it could happen easily.
                                       The  area  under the hopper  of  the
                                       unit had a number of cross beams and
                                       other  obstacles.   While trying  to
                                       get through this area, the box could
                                       easily be grabbed.   At the time the
                                       box  was  grabbed,   the  individual
                                       would  probably be hanging on to one
                                       of  the metallic  cross  beams.   It
                                       would  be possible to suffer a fatal
                                       shock under these conditions.

     As is so often the case, the various types of hazards occur frequently
in groups.  Just 3 feet from the location of this slide, there is a missing
guard rail.  While concentrating on ways not to fall off the guard rail,  an
individual may not give any thought to the electrical hazard.
                                     62

-------
SLIDE 4-13
                                       When  making measurements downstream
                                       of electrostatic  precipitators,   it
                                       is very important that all probes be
                                       grounded.    The highly charged part-
                                       iculate leaving the precipitator  can
                                       impart  a  high static charge on  the
                                       probe.  When the individual touches
                                       the probe, a shock can occur.  While
                                       the static shock is usually not life
                                       threatening, it may cause the person
                                       to  jump backwards and fall off  the
                                       sampling  platform or hit his or  her
                                       head on the various obstacles  often
                                       found around the platform.

      It  is surprising how many stack samplers and field inspectors do  not
respect the potential safety problems  related to static  electricity.   It
is  usually prudent to electrically bond all probes to the duct  where  the
port is located.
SLIDE 4-14

                                       This  is a electric vibrator type of
                                       rapper  on the roof of  an  electro-
                                       static  precipitator.   There  is  a
                                       small  ground  wire going from  both
                                       the  box and the rapper shaft  to  a
                                       grounding  cable out of view of this
                                       slide.  This protects against shorts
                                       in    the   vibrator   which   could
                                       seriously  shock anyone  touching  a
                                       rapper.

                                       Similiar  grounding  wires  will  be
                                       attached  to  all bus ducts  on  the
                                       precipitator roof.   They are neces-
                                       sary  to drain off the charge  which
                                       builds  up  on the bus duct  due  to
                                       sparking  from the high voltage line
                                       suspended in the center.

There is absolutely no need for the inspector to touch anything  while on a
roof  of  a precipitator.   It is possible to check  rapper  intensity  and
sequence, to evaluate air infiltration through access hatches, and to check
the  operation of the purge air blowers without touching any of the compon-
ents.  Often contact will occur while a person is attempting to negotiate a
path across the roof which is crowded with bus ducts, conduit, rappers, and
transformer-rectifier sets.  Although the very large majority of components
are properly grounded, contact with them should be avoided.
                                    63

-------
 SLIDE A-I
                                        This  is  a  partial  view of  the  inside
                                        of  an   electrical cabinet  for   one
                                        field of an  electrostatic  precipita-
                                        tor.   On  some  older  units,   it   is
                                        necessary  to  open the cabinet   to
                                        determine  if  the  field is on  manual
                                        or  automatic control.    This can   be
                                        determined  from the position  of  the
                                        switch   shown  in this   slide.     THE
                                        CABINET  SHOULD  BE OPENED  ONLY   BY
                                        QUALIFIED  PLANT  PERSONNEL,  NEVER BY
                                        THE  INSPECTOR.    Electrical   compo-
                                        nents within  easy reach can   be   at
                                        more  than  400  volts.
      Hazards from electrical  cabinets  also  occur  when  inspectors  attempt  to
 measure  the  fan motor currents  for scrubbers  and  baghouses.   Opening   an
 electrical  cabinet   to use an inductance ammeter should  be  done  only   by
 qualified  plant personnel,  never  by  the inspector.    As with  the   cabinet
 shown  above,   they  can have  high voltage components around  the lines  being
 measured.
 SLIDE 4-16
                                        When    walking   around   areas   where
                                        flammable vapors are  possible,   in-
                                        spectors   should  wear  safety   shoes
                                        designed   to prevent the   accumula-
                                        tion  of static  electricity.    Before
                                        inspecting  areas  similar   to  that
                                        shown  in this   slide,   discuss  the
                                        type   of  shoes  to be worn with plant
                                        personnel.
Source: National Audiovisuals Center
                                      64

-------
SLIDE 4-17
                                       Most   plants have areas where explo-
                                       sions could be initiated by smoking.
                                       While the plant personnel are warned
                                       repeatedly  about  such  areas,   the
                                       inspector   may  not  recognize   the
                                       hazard.    DO NOT TAKE SMOKING MATER-
                                       IALS  ON  INSPECTIONS.
SLIDE 4-18
                                       This   is  a  portable thermocouple  for
                                       measuring  gas  temperature.    It   is
                                       one of a  number of  common  inspection
                                       instruments  powered  by   batteries.
                                       It  should  not  be taken into   poten-
                                       tially explosive areas  because   it
                                       can initiate an explosion.

                                       It  is necessary to  obtain  a hot work
                                       permit is  necessary to take  battery
                                       powered  instruments  in   to   areas
                                       around some air pollution   control
                                       systems.    Potential problems should
                                       be  discussed fully   before   taking
                                       the  instruments into such   areas.
                                       The  most  common types of  battery-
                                       powered  instruments are pH   meters,
                                       flashlights,  and thermocouples.
                                    65

-------
SLIDE 4-19

                                       It  is sometimes necessary during  an
                                       inspection to get a sample of  a sol-
                                       vent or coating to analyze for vola-
                                       tile content.   It is also common  to
                                       get a sample of fuel oil to measure
                                       the sulfur content.

                                       When  transferring flammable liquids
                                       or dusts from a storage vessel to   a
                                       sample  container it is possible  to
                                       build  up  a high static voltage  on
                                       the receiver.   If the entire  system
                                       is not grounded and bonded properly,
                                       an explosion is possible.


     This  slide shows a storage drum and the small clip which is meant  to
be attached to the receiver.    This particular clip is so rusted that it  is
very unlikely that it could provide a proper electrical connection.

     When drawing a sample,  the funnel (if  any)  must be made of a  con-
ductive material and must be  electrically bonded to the rest of the system.
It  is also important to prevent static electrical sparks originating  from
persons  near the sample container.   The samples should be drawn by   plant
personnel, not the inspector.
SLIDE 4-20
                                       This  is another view of the storage
                                       drum  shown in the  previous  slide.
                                       Close  examination reveals that   the
                                       line   leading  from  the  grounding
                                       stake   is  not  connected  to   the
                                       storage  drum.   Since  the  storage
                                       drum,  funnel,  and receiver may not
                                       be at the same potential,  an  explo-
                                       sion is possible.

                                       Whenever  it is noted that grounding
                                       and bonding are incomplete,  the in-
                                       spector  should  notify  responsible
                                       plant personnel immediately.  If the
                                       plant  personnel persist  in  taking
                                       the  sample,  the  inspector  should
                                       leave the area immediately.
                                     66

-------
SLIDE 4-21
                                       This   is a  relatively small fan on  a
                                       wet  scrubber system.    If  a fan  ap-
                                       pears to be vibrating severely,   the
                                       inspector should notify responsible
                                       plant   personnel  immediately   and
                                       leave the area.   When a fan disinte-
                                       grates,   metal  shrapnel-like  frag-
                                       ments  can  be sent  over a  wide area,
                                       even  through walls.

                                       Excessive  fan vibration  can  occur
                                       because  of  aerodynamic conditions or
                                       various  physical insults.    The most
                                       common   physical  problems  include
                                       bearing  failure, wheel erosion, and
                                       wheel deposits.   Operating a fan at
                                       too  high a  speed can  also  cause  the
                                       fan  to disintegrate.

      Fan  disintegration often occurs during start-up of  the unit.    It is
generally prudent to stay some distance away from  fans when  they  are  being
started.
SLIDE 4-22
     HIGH VOLTAGE LINES
High  voltage  tracks are common at
steel  mills  and  other  plants  in
which  it is necessary to  move  hot
material on a routine basis.

The  high voltage line can be within
reach   while  walking  through  the
mill.  Even though there are warning
signs, inspectors not  familiar with
the  plant could  conceivably  touch
the line.   In some plants, it would
be  possible  to accidently step  on
these high voltage tracks.

High  voltage  lines  are  sometimes
found in the vicinity of air  pollu-
tion  control  devices  and  stacks.
Care  is  necessary  whenever  using
long   measurement  probes  such  as
pitot tubes.
                                     67

-------
SLIDE 4-23
                                       Many  air pollution control  systems
                                       are located at the highest locations
                                       within  the  plant.   Lightning  can
                                       strike the structures in the area of
                                       the collector.  Whenever threatening
                                       weather   exists,     these   exposed
                                       locations should be avoided.   Avoid
                                       these  exposed locations when the an
                                       electrical storm is in the area.
SLIDE 4-24

                                       There  are several possible ways  to
                                       be  exposured to ionizing radiation
                                       such as gamma rays and beta  partic-
       IONIZING RADIATION            les.   Gamma ray sources are used as
                                       hopper level detectors on some large
                                       electrostatic precipitator and fab-
                                       ric  filter systems.   Gamma ray  in-
                                       struments  are used to  continuously
                                       monitor process feed  rates, material
                                       densities,  and  tank levels.   Beta
                                       gauges  are used for  the  continuous
                                       monitoring of film thickness.

      It has also been reported that some dusts collected in air  pollution
control  systems are somewhat radioactive because of the components of  the
ash or dust.   It should be easy for an inspector to avoid any  significant
exposure to ionizing radiation.
                                     68

-------
SLIDE 4-25
                                       This  is the source part of a  gamma
                                       ray  detector  on the hopper  of  an
                                       electrostatic precipitator.  It con-
                                       tains  a small amount of cesium 137,
                                       a radioactive substance.  Cesium 137
                                       is constantly disintegrating by  re-
                                       leasing gamma rays.   The gamma rays
                                       are   focused  into  a  narrow  beam
                                       which  passes to a detector  on  the
                                       other side of the hopper.   The pre-
                                       sence  of  solids in the  hopper  is
                                       indicated  by the absorption of some
                                       of the gamma rays.

     All instruments of this type have a shutter which prevents release  of
the  gamma rays when  maintenance is being performed (the source can not be
"turned off").   The entire source is shielded to reduce exposure to  gamma
rays  in  the  immediate vicinity of the  monitor.   All  instruments  must
satisfy  a minimum radiation level within one foot of the instrument.   Be-
cause of these design characteristics,  the instruments are considered safe
for a number of applications.   Nevertheless, the regulatory agency inspec-
tor  has  no  need to be close to the instruments and  should  avoid  close
contact.   If a detector has been damaged , the entire area surrounding the
Monitor should be avoided because the protective shielding may no longer be
effective.
SLIDE 4-26
""""'  mmmft
 '
                                       This  is  a gamma  ray  sludge  feed
                                       monitor at a sewage treatment plant.
                                       The  source of gamma rays is located
                                       in  the arm above the belt  and  the
                                       detector  is located below the belt.
                                       The quantity of solids is related to
                                       the gamma ray absorption.

                                       It is obvious that placing hands  or
                                       arms  between  the  source  and  the
                                       detector.   would  result in  direct
                                       exposure to the gamma ray beam.   It
                                       would also bring the individual into
                                       contact with moving equipment.

     This  type  of instrument is shown because (1) it is the  most  common
      of gamma ray source found during inspections of air pollution sources
     (2) it has the largest open path between the source and the  detector.
       is no reason for an air pollution control agency inspector to be  in
    immediate vicinity of any of these instruments.

-------
SLIDE 4-27
                                       Direct contact with large quantities
                                       of  collected  solids (or even  coal
                                       piles) should be avoided.   There is
                                       a very slight possibility that  some
                                       of  these will have significant rad-
                                       ioactivity levels.  There are also a
                                       number of other accidents and health
                                       hazards associated with large  piles
                                       of  dust  and  solids  (burns,  skin
                                       irritation, falls, asphyxiation, in-
                                       halation  of toxic dust,  entrapment
                                       in submerged rotating equipment).
                                     70

-------
SLIDE 5-1
         HEAT STRESS
                                       Many  air pollution control  systems
                                       operate at elevated gas temperatures
                                       and many operate in close  proximity
                                       to  hot  process  equipment.    Steam
                                       clouds  are common near control  de-
                                       vices.  Furthermore, the areas which
                                       must  be inspected are generally  in
                                       the highest parts of the plant which
                                       means that climbing is almost inevi-
                                       table.   Due to these factors,  heat
                                       stress is a potential threat  to  the
                                       inspector.   This  lecture  concerns
                                       recognition  of the symptoms  of heat
                                       stress  onset and ways  to  minimize
                                       the risk of heat-related injuries.
                 HEAT SOURCES
      • Steam
      • Ambient Temperature
      • Radiant Energy
      • Metabolic Heat
SLIDE 5-2

                                       Heat  stress is the additional  load
                                       placed  on  bodily functions as  the
                                       body  attempts to  maintain  correct
                                       internal temperatures.   This is not
                                       easy; there are significant  sources
                                       of  heat present in every industrial
                                       setting.   This slide lists the four
                                       most common heat sources encountered
                                       during the inspection of air  pollu-
                                       tion control systems.

                                       Radiant heat from hot ducts, control
                                       devices and process equipment can be
                                       a significant problem.  The level of
                                       heat  radiation  is related  to  the
                                       FOURTH  POWER  of the temperature of
                                       the hot equipment.  -This means that
                                       uninsulated  equipment in the  range
                                       of  300 to 2000 °F can radiate  very
                                       large heat levels.

     Metabolic heat is the energy released during heavy work such as climb-
ing,  breathing with respirators, taking measurements, and lifting portable
inspection equipment.

     Steam is very common around air pollution control systems and can be a
major source of heat energy .    Steam makes the normal bodily cooling func-
tions  difficult  because  it raises the humidity in the  vicinity  of  the
control  system.   These varied sources of heat make it possible to  suffer
heat stress even when the ambient temperature is relatively low.
                                     71

-------
SLIDE 5-3

                                        It  is possible for the inspector to
                                        suffer  the  onset  of  heat  stress
                                        while  plant  personnel seem  to  be
     ACCLIMATIZATION TO HEAT           having no difficulties at  all.  In-
                                        spectors  are often more susceptible
                                        to  heat  stress because it  is  not
                                        possible  for them to  acclimate  to
                                        plant conditions.

                                        Acclimatization   involves    actual
                                        physiological  adjustments  of   the
                                        body  and results in enhanced toler-
                                        ance to heat.   It usually takes one
                                        to  two weeks of exposure for  total
                                        adjustment.

     The  majority  of the changes  involved in acclimatization  take  place
during  the first two days.   Unfortunately,   the enhanced   capability  to
with-stand  heat  is also lost  quickly  as most body readjustments occur  in
just  two  days.   Therefore,   the  agency field inspector does  not  remain
acclimated even though he or she  is regularly exposed (once a week)  to hot
conditions.
SLIDE 5-4
       FACTORS WHICH INCREASE
    SUSCEPTIBILITY TO HEAT STRESS
  Lack of Acclimatization
  Chemical Exposure
  Noise Exposure
  Obesity
  Age
  Mean or Respiratory Disease
  Alcohol Consumption
  Fatigue
  Humidity
  Altitude
Factors which can contribute to heat
stress include exposure to chemicals
such as carbon monoxide and exposure
to  excessive noise.   The  physical
condition of the individual is  also
important.   Conditions such as obe-
sity,  heart disease, alcoholic con-
sumption,  and fatigue can aggravate
the  conditions.  Susceptibility  to
heat  stress usually increases  with
age.
                                      72

-------
SLIDE  5-5
        HEAT-INDUCED ILLNESSES
  • HEAT CRAMPS
  • HEAT EXHAUSTION
  • HEATSTROKE
 The  three major heat  induced  ill-
 nesses   are  listed in order of  in-
 creasing severity.   A brief synopsis
 of  the  symptoms of  developing  prob-
 lems  and  emergency  treatment  for
 each  problem  are  discussed in  the
 following slides.
SLIDE 5-6
         HEAT CRAMPS
       Cause: Loss of Salts
    Symptoms: Muscle Spasms
    Treatment: Rest and Drink Water with 0.
            Salt
Sweating  causes depletion  of   salts
from the body vwhich  in  turn reduces
tissue fluid levels and  causes   mus-
cle  spasms.   The  spasms  are   most
common  in  the  extremities,   back,
and abdomen.

If  these symptoms are   experienced,
the inspection should be interrupted
immediately and a cool place to rest
should be found.  The affected  indi-
vidual  should drink  water  contai-
ning 0.1% by weight salt (1  teaspoon
per 5 quarts water).
                                     73

-------
SLIDE 5-7
                                         Heat   exhaustion  results  from  the
                                         loss   of body water and   salt.   The
                                         dilation  of blood vessels  results
                                         in    decreased blood circulation and
                                         reduced blood supply to  the cerebral
                                         cortex.   This  can cause an indivi-
                                         dual  to collapse.

                                         The initial symptoms include  rapid
                                         pulse with low blood pressure, head-
                                         ache,   nausea, fatique,  clammy skin,
                                         and   vomiting.  Obviously,  all  in-
                                         spection  activities should be stop-
                                         ped and immediate aid obtained  when
                                         these symptoms are noticed.

    The individual should  rest in a cool place which is not less than 75°F.
It may  be necessary to get further treatment from plant personnel or  other
qualified medical personnel.
     HEAT EXHAUSTION

     Cause: Decreased Blood Circulation from
           Dehydration and Vasodilation

   Symptoms: Fatigue, Nausea, Vomiting,
           Headache, Dizziness, Clammy
           Skin, Fainting, Rapid Pulse, Low
           Blood Pressure, Mental
           Disturbances

   Treatment: Rest in Cool Area, Drink Water
           with 0.1% Salt, Get Medical
           Attention
SLIDE  5-8
                                         Heat  stroke is an extremely  serious
                                         condition.    It  is  caused  by  the
                                         failure   of the body cooling  system
                                         and   the   uncontrolled rise in  body
                                         core  temperature.   It can  be  fatal
                                         if not treated promptly.

                                         The   symptoms are a hot,  dry  skin,
                                         high  body   temperature,  confusion,
                                         convulsions,   loss of consciousness,
                                         and coma.

                                         The   treatment  usually consists  of
                                         immediate  cooling by  immersion  in
                                         chilled   water with massage or wrap-
                                         ping  in wet sheets and fanning.   It
                                         is  often  necessary  to  treat  for
                                         shock.

      It  should be apparent  that medical aid should  be obtained as  rapidly
as possible when there is a  possibility for  heat stroke.   It should be re-
memebered  that most air pollution control equipment is located in elevated
and  remote portions of the  plant.   It may  be difficult to rapidly move  an
unconsciousness individual to  a  cool air and difficult to get cool water up
to a stricken individual.    For  this reason,  it is  necessary to start  for
protected areas and medical  attention at the first sign of trouble.
     HEATSTROKE

   Cause: Failure of Perspiration System
        Resulting in Rise in Body
        Temperature

Symptoms: Hot, Dry Skin; High Body
        Temperature; Loss of
        Consciousness; Convulsions;
        Coma

Treatment: Immediate and Rapid Cooling, Get
        Medical Attention, Treat for Shock
        if Necessary
                                       74

-------
 SLIDE 5-9
                                       One way to minimize the risk of  the
                                       various  types  of heat stress  just
                                       discussed  is to avoid hot areas  as

  M.N.M.Z.NO THE R.SK OF HEAT STRESS    Z^^g^ the'i^ti
                                       hot sources during the early part of
                                       the  day when the  ambient  tempera-
                                       ture  is low.   While walking to the
                                       control systems,  avoid the the  hot
                                       areas  of the process.   Some of the
                                       most common areas which are hot  are
                                       walkways  near furnaces and rotating
                                       kilns,  and the roofs of air  pollu-
                                       tion control devices.

     Pitot  traverses on hot ducts can sometimes be a cause of heat  stress
 since the inspector could spend up to an hour at the sampling ports.  If it
 is  necessary to be close to the stack or duct during the  traverse,  there
 Can  be substantial exposure to heat.   One way to minimize problems is  to
 mark off the probe and perform all calculations in an area which is  cooler
 than  the sampling platform.   If the radiant heat is very high,   the pitot
 traverse should not be conducted at this location.

    All  inspectors  should be screened for hot weather work as part  of  a
 medical   monitoring program.    This should identify any  individuals  with
 Problems  such  as  heart and respiratory diseases or any  other  condition
 which makes that person particularly susceptible to heat stress  problems.

 SLIDE 5-10
                                       When  working near a radiant  source
                                       of  heat, such as a duct  or  stack,
                                       protective clothing may be necessary
 SELECTING THE APPROPRIATE CLOTHING   to reduce the potential exposure.

                                       When working near nonradiant sources
                                       of  heat  light clothing  should  be
                                       worn  so that evaporative  cooling is
                                       facilitated.   In general,   when the
                                       temperature is less than 100 °F  the
                                       clothing  should be light  and  loose
                                       fitting.   When  the temperature  is
                                       greater than 100 °F, it should cover
                                       as  much of the body as possible  to
                                       decrease  convective heat   transfer
                                       from the surrounding air.

     Synthetic  materials should not be worn in areas where there   is  high
radiant   heat.   It  is possible for some of the synthetics to bond to  the
8kin  when  the temperature is  very high.    The work clothes should be  com-
Posed primarily of cotton.
                                      75

-------
SLIDE 5-11

                                       Individuals  working  in  hot  areas
                                       must  drink sufficient fluids to  re-
                                       place  that  lost through  sweating.
                                       Nonacclimated  people must take  the
 GENERAL PRECAUTIONS TO MINIMIZE       precaution of  increasing their salt
           HEAT STRESS                 intake  to avoid dehydration.    Heat
                                       cramps   can  result  from   drinking
                                       large  quantities  of unsalted water
                                       because of the muscle tissue  fluids
                                       become  diluted.   Salt may be  taken
                                       with  meals,  in  electrolyte  beve-
                                       rages,   or in salted water.   Fluids
                                       should  be taken every 30 minutes and
                                       one   person may consume up to 2 gal-
                                       lons  per day.

     Another  precaution  that can be  taken  to reduce the  chance  of  heat
stress is to take frequent rest breaks when  working in hot areas.  The work
should  be  interrupted  whenever symptoms of the onset of heat  stress  are
observed.
SLIDE 5-12
                                       Cold  stress  is the loss of body heat
                                       in  situations  of  overexposure  to
          COLD STRESS                  cold.    It   can lead to skin injury,
                                       loss  of  extremities, and even death.
                                       For   air pollution control  inspec-
                                       tors,  the principal problem is skin
                                       injuries.
                                    76

-------
                MECHANISMS
                     OF
              BODY HEAT LOSS
    • Radiation
    • Conduction
SLIDE 5-13

                                        The five mechanisms for loss of body
                                        heat are listed in this slide.   The
                                        radiation  to surroundings increases
                                        substantially as the ambient temper-
                                        ature drops.   This is again a funct-
                                        tion  of  the  fourth power  of  the
                                        person's  temperature and  the  sur-
                                        rounding  temperature.    Conduction
                                        occurs  while standing in a layer of
                                        water  or while holding on  to  cold
                                        objects  (such  as guard  rails  and
                                        support beams).

     The  convective  transfer of heat  from the body increases as the  wind
speed  increases.   It is important  to  stay in protected areas to  minimize
this  mode of heat loss.   Respiration  results in heat loss since the  cold
air is heated to body temperature before it is released.
     Convection
     Evaporative Cooling
     Respiration
SLIDE 5-14
       FACTORS WHICH INCREASE
    SUSCEPTIBILITY TO COLD STRESS
 • Lack of Habitation
 * Heart and Respiratory Conditions
 • Fattgue
 • Alcohol Consumption
 • Inadequate Food
 • Dehydration
                                       Some of  the  factors which affect  an
                                       individual's  susceptibility to cold
                                       stress   are   listed in  this  slide.
                                       People   do not acclimate to cold  as
                                       they do  to heat,   however,  there is
                                       some  habituation,     that  is,  in-
                                       creased   tolerance for  cold  condi-
                                       tions.

                                       Individuals   with   heat and/or  res-
                                       piratory problems will be  more  at
                                       risk  from cold stress than  others.
                                       Alcoholic consumption should be min-
                                       imized.   Fatigue,   inadequate food,
                                       and  dehydration also make an  indi-
                                       vidual more  susceptible.
                                     77

-------
          COLD INDUCED AILMENTS
   • FROSTBITE
   • HYPOTHERMIA
SLIDE 5-15

                                        These   are  the two  major   ailments
                                        caused by extremely cold conditions.

                                        Frostbite  is  the freezing  of   some
                                        part of the body.  Ice crystals  form
                                        in  the cells of the affected tissue.
                                        Usually  this occurs in the   extrem-
                                        ities  such as ears, hands, and parts
                                        of  the face.   There are three   de-
                                        grees  of frostbite:  frostnip,   sup-
                                        erficial  frostbite and deep frost-
                                        bite.    Frostnip  affects  only   the
                                        skin while superficial frostbite can
                                        affect  tissue just below the skin.
                                        Deep   frostbite affects deep tissue
                                        including even the bones.

     Hypothermia  is  the lowering of the body's core temperature.    This can
result in mental  and physical deterioration   to the point of collaspe.    It
is often fatal.
SLIDE 5-16
       FROSTBITE SYMPTOMS
        Frostnip: Red to Pate or White Skin,
               Tingling, Stinging or Cold
               Sensation Followed by Numbness
 Superficial Frostbite: White to Grey-White Skin. Waxy
               Skin and Lack of Sensation
    Deep Frostbite: Skin and Tissue Pale, Solid
               Blisters and Swelling
                                        The symptoms of frostbite are  list-
                                        ed  in  this slide.   Note that there
                                        is  a   progression in the  type  and
                                        severity  of these conditions.

                                        Whenever   these symptoms are  noted,
                                        the inspection should be stopped and
                                        a protected location found.
                                      78

-------
SLIDE 5-17
      TREATMENT OF FROSTBITE

         Frostnip: Apply Body Heat

  Superficial Frostbite: Apply Body Heat
     Deep Frostbite: Remove to Warm Area, Bathe
                Affected Area with Warm Water or
                Apply Warm Packs, Qet Medical
                Attention
The  immediate  treatment  of  frost-
bite  is  listed in this  slide.   To
treat frostnip,  apply body heat  by
placing   the affected part in direct
contact   with skin of an area  which
is warm,    such as the chest or arm-
pit.  The treatment for  superficial
frostbite  is identical  to that for
frostnip.

For  deep  frostbite,   the   person
should be removed to a warm area and
the  affected  area bathed  in  warm
water (between 104 and 106 °F).   An
alternative  to bathing the area  is
to use wet packs.
SLIDE  s-is
  SYMPTOMS OF HYPOTHERMIA

        >95° Uncontrollable Shivering and
             Increase In Respiration
       90-95 °F Disorientation, Apathy, Dilated
             Pupils, Diminished Shivering and
             Diminished Respiration

       86-90 °F Semi-Consciousness, Muscular
             Rigidity and Further Pupil Dilation
       <86 °F Unconsciousness and Diminished
             Respiration

       <80°F Little or No Respiration
The   symptoms of hypothermia  change
with   the  body's core   temperature.
There  is a logical   progression  as
the core temperature  drops.

As  the  body temperature  drops  to
95°F,  shivering increases to uncon-
trollable   levels  and  respiration
increases.

Between 90 and 95 °F, disorientation
and apathy occur.   Diminished shiv-
ering  and respiration   occur.   The
pupils become dilated.
      Between 86 and  90 °F,   there is muscular rigidity and further dilation
 °f the  pupils.   Semi-consciousness may  occur.  Below 86  °F,  respiration  is
 very  diminished and  the person may be  unconscious.

      The  treatment  of very mild hypothermia consists of  feeding warm beve-
 tages and replacing  all wet clothing with dry.   In more  severe cases,  the
 Person   should be placed in a warm bath  (approximately 105 °F)  or  wrapped
 with  warm moist towels.  Medical aid should be obtained immediately.
                                       79

-------
SLIDE 5-19
WINOCHILL CHART
MNO8K8O
IMFH)
8
10
16
10
26
30
38
40
48
80

32
28
18
13
7
3
1
-1
-3
-3
-4
23
20
7
-1
4
-to
-13
-IB
-17
-16
-18
14
10
-4
-13
-16
-24
-27
-28
-31
-32
•33
VK*(
8
t
-16
-38
-32
-37
-41
-43
-48
-48
-47
HI*
-4
4
-28
-37
-44
40
-«
47
48
41
42
ffflA
-13
-18
-37
-48
47
+*
48
-71
-74
-76
-78
TVfl
-32
-28
-48
41
-70
-77
42
48
47
48
41
1 F)
-31
-37
48
-73
43
40
47
48
-103
-1O4
-108
-40
-47
-70
48
46
-104
-108
-113
-116
-118
-120
-48
46
41
47
-108
-117
-133
-137
-131
-132
-134

-"
48
42
-108
-121
-130
-137
-142
-146
-147
-148
For Property CMtatf Unto ConiiamMi Vwv On« DWK
Fran Dnpf Ow«v
OANOIM FROM FREEZING OF 8XFO88D FL88H
                                       Routine  inspections of  air  pollu-
                                       tion control equipment should not be
                                       done  when the wind chill factor  is
                                       less  than -20 °F.    The chart shown
                                       on  this slide allows a  calculation
                                       of  the wind chill  factor using  the
                                       temperature and the wind speed.

                                       At  wind chill factors greater  than
                                       the  -20 °F there is little  danger,
                                       for people who are  properly clothed,
                                       that   exposed  flesh  will  freeze.
                                       Below -20 °F,   there is the risk  of
                                       cold  stress.    It  is also  possible
                                       that  observations  and  measurements
                                       made under very cold conditions will
                                       not  be complete or accurate.    Some
                                       portable instruments are not  inten-
                                       ded  for  service  under  very  cold
                                       conditions.
SLIDE 5-20

                                       Clothing  should be layered  to   trap
                                       warm  air and to prevent   conductive
                                       heat loss.   In   addition,   layering
 SELECTION OF APPROPRIATE CLOTHING    allows  regulation  of warmth.    When
                                       it  gets too warm,   one simply  takes
                                       off  the  appropriate layers.   The
                                       outer  layer should be wind proof,
                                       and  in  wet weather, water proof.
                                       Wet  clothing causes rapid  loss  of
                                       body  heat due to evaporative   cool-
                                       ing.  The inspector should be   aware
                                       that  heavy perspiration may dampen
                                       clothing enough  to  cause evaporative
                                       cooling.   Heat   regulation  can  be
                                       accomplished  by removing  layers and
                                       by  opening  closures at  neck and
                                       wrists.

     The head should always be covered since substantial heat loss  occurs
through  the head.    Insulated boots should be worn.    Steel toed boots can
cause rapid chilling of the feet.
                                     80

-------
 SLIDE 5-21

                                       During  the  inspection,   the  work
                                       outside  should  be alternated  with
                                       the work inside so that long periods

GENERAL PRECAUTIONS TO MINIMIZE THE    ^l*** ^ "Ot T*  in
        DICK nc rni n CTRP«5R            areas.   While inside,  warm
        RISK OF COLD STRESS            should  be consumed to help warm the
                                       body.   The clothing should not  be-
                                       come damp from perspiration while in
                                       the warm areas.

                                       Regular  checks  for  the  onset  of
                                       frostbite  should be made.    The in-
                                       spector should not,  under  any  cir-
                                       cumstances,  work alone. An accident
                                       could  trap an inspector in an  iso-
                                       lated  portion of the plant and  re-
                                       sult  in  extended exposure to  cold
                                       before he or she is found.
                                    81

-------
82

-------
SLIDE 6-1
                                       A  wide variety of potential hazards
                                       may be encountered while  inspecting
                                       air  pollution control systems.   Un-
                                       like  workers who might work at   the
                                       same  station for 40 hours per week,
                                       inspectors  are not usually  subject
                                       to  chronic  exposure  to  the   same
                                       chemicals.   Rather, they are poten-
                                       tially at risk from acute  exposures
                                       to  a large number of chemicals.   It
                                       is  important for each inspector   to
                                       know the warning properties of  these
                                       chemical   and   how    to   choose
                                       respirators which will provide   pro-
                                       tection from  various types of  chem-
                                       icals and different concentrations.

     One of the fundamental principles of industrial hygiene is that possi-
ble  exposures should be minimized or eliminated through the application of
engineering controls.   In the case of the field inspector for a regulatory
agency this is not a realistic possibility.   Most exposures occur  because
of  fugitive  leaks  of the pollutant-laden gas stream out  into  the   area
immediately surrounding the air pollution control system.  These conditions
occur  by accident and often are not identified by plant personnel.   Other
sources  of exposure are contact with the downd'raft from nearby  stacks  or
rising clouds of toxic pollutants released from intermittent process opera-
tions.   Both  types of exposure result when inspectors are present on  ele-
vated  platforms surrounding air pollution systems or stack sampling  loca-
tions.   In a sense,  the inspector is at risk from the discharge points of
the  very engineering controls which are intended to protect plant  person-
nel.

     Since the exposures can not be easily limited by engineering controls,
the  inspector must substitute awareness of the potential problem areas and
awareness of the warning properties  of all chemicals present in the gener-
al area.   The inspector must know when certain areas should be avoided and
what  respirators and other protective clothing to use in the  areas  which
must  be visited.   The choice of respirators is complicated by the lack of
monitoring  data for the types of materials present.   The  conditions   are
highly variable and this makes monitoring data subject to error.   Further-
more,  there is rarely any monitoring data in the specific locations  where
the inspector may experience the most significant exposure.

     The  inspector who fails to use a respirator when necessary or selects
the  improper respirator can be at substantial risk.    Synergistic action
between  the  300 to 600 common chemicals that may be inhaled by  a single
individual  during a year could result in problems despite the small  quan-
tites of each that may have deposited in the respiratory tract.   Also,   if
the  inspector  is hypersensitive to any chemical,  he or she  has  a   good
chance of encountering this material at least once per year.  The inspector
does not ever get an opportunity to acclimate to the various chemicals.
                                     83

-------
SLIDE 6-2
                                       This  is  one of three  basic  rules
                                       that  field personnel should  follow

                                                             P°11Uti°n
    EVERY SITUATION SHOULD BE
      APPROACHED CAREFULLY
                                       This  rule means that the  inspector
                                       should  bring  the  proper  personal
                                       protective  equipment necessary  for
                                       the  areas  to  be  inspected.   The
                                       agency file for the plant should  be
                                       reviewed before starting the inspec-
                                       tion.  Files should contain lists of
                                       the chemicals which could be encoun-
                                       tered during the inspection.   Based
                                       on  the list and the recommendations
                                       of the plant personnel,  the  proper
                                       type of respirator can be selected.

     Prior  to  entering  each specific area of the  plant,  the  inspector
should  consider  what potential problems can  exist.   Partially  confined
areas should be avoided to the extent possible.   While walking to the area
of  the pollution control equipment,  avoid  plant operations not  directly
related to the inspection.
SLIDE 6-3
                                       The  work should be interrupted when
                                       the inspector encounters any of  the
                                       non-specific  symptoms  of  exposure
                                       listed  in this slide.   While these
                                       ill  feelings may not be due to  any
                                       exposure   which  occurred  at   the
                                       plant,  the inspector can not afford
                                       to base his actions on this  assump-
                                       tion.  The inspector should go IMME-
                                       DIATELY  to a well-ventilated  area
                                       and reconsider the potential inhala-
                                       tion  hazards.   Remember  that  the
                                       inspector  may  feel ill before  the
                                       plant personnel because they  accli-
                                       mated  to the conditions and are not
                                       exposed  to  as wide  a  variety  of
                                       materials as  the inspector.

     It  is important that the inspector be aware of how he or she is feel-
ing  during the inspection.   Many of the pollutants have very poor and non-
specific  warning properties.   The initial mild feelings of discomfort  can
quickly  develop  into very serious situations.   At the  first  feeling  of
discomfort, the inspector should go to a well-ventilated are immediately.
 HALT WORK IMMEDIATELY
     IF YOU HAVE ANY
   OF THESE SYMPTOMS:

     Headache
     Nausea
     Drowsiness
     Chest Pains
     Shortness of Breath
     Lightheadedness
     Eye or Nose Irritation
Find A W«n Ventilated Area Immediately
                                     84

-------
 SLIDE 6-4
IF THE NECESSARY PERSONAL PROTECTIVE
EQUIPMENT IS NOT AVAILABLE THEN AREAS
  OF POTENTIAL RISK MUST BE AVOIDED
                                       This  is  the  third  basic  rule.    If
                                       the  necessary  protective  equipment
                                       is not available,   or  if the inspec-
                                       tor  does not have  the proper train-
                                       ing in the  use  of this equipment,  no
                                       areas  of potential risk  should  be
                                       entered.

                                       One  might  expect that plant person-
                                       nel  would  restrict entry  to  such
                                       areas.  However, in a  few cases  they
                                       do not recognize that  these are  haz-
                                       ards since  they are so familiar  with
                                       the  conditions.    Furthermore,   the
                                       inspector  should not   abdicate   all
                                       responsibility  for safety to anyone
                                       else during an  inspection.

     Plant personnel often provide the necessary respirators  to  inspectors
without  realizing that the individual has had no  previous training in   the
use of the respirators and has not had a medical examination  to demonstrate
his  capability  to  withstand the stress caused by  the   respirator.   The
inspector  should  advise plant personnel in either  case and  the  areas  of
Potential exposure should be avoided.  This will probably  mean that a large
Portion of the inspection can not be done as planned.

SLIDE .6-5

                                       The  upcoming series of slides  con-
                                       cern  the  most common  areas where
                                       exposure  to chemicals  can occur  when
                                       inspecting  air pollution  systems.
                                       The  inspector  must recognize these
                                       areas  so that  potential  exposures
                                       can be avoided  entirely or minimized
                                       by using  respirators.

                                       The  list  presented in  this slide
                                       presents  some of these common areas.
                                       It  is  readily apparent  that  most
                                       sources   include  a number  of  such
                                       areas.

     The  term  "partially confined area" has been developed  for this  pro-
gram  and will not be found in the standard industrial hygiene  literature.
This  phrase is necessary to characterize the unique hazards  which  can  be
found  near air pollution control systems.   Such  areas must  be  approached
     cautiously.
           COMMON AREAS WITH
           INHALATION HAZARDS
   • Elevated Sampling Platforms
   • Areas Adjacent to Process Vents and Discharge Pofnts
   • Partially Confined Areas
   • Fugitive Process Emissions
   • Fugitive Emissions from Solids Discharge Equipment
                                      85

-------
 SLIDE 6-6
                 m*
                                        This   is   a   photograph  of  a  stack
                                        sampling   platform on a  foundry  wet
                                        scrubber  system.  Out of view to the
                                        right  of  the  slide are several small
                                        roof monitors which vent the process
                                        operations below.  The emissions can
                                        drift  across  the sampling platform.

                                        An  inspector could spend more  than
                                        an hour on the platform while making
                                        a  pitot  traverse.   Stack  samplers
                                        could  easily  spend 6 to  10 hours  on
                                        the platform  while performing a com-
                                        plete  Method  5 test.

      Due  primarily to the length of the possible  exposure, the proximity to
 the   process  vents,  and the toxicity of the  pollutants released  from  the
 vents during  certain periods,  it is advisable to use respirators.    Stack
 samplers  may need to take frequent breaks to reduce the discomfort of  the
 respirators   cause  over a 6-10 hour period.   Field inspectors should  at-
 tempt to  find a different location for making the pitot traverse.   If this
 is  not possible,  then all activities associated with the traverse that do
 not   have to  be conducted directly at the sampling platform should be  done
 in a  protected location.   For example,  it would be easy to calculate  the
 number  of  points  necessary and to mark off the pitot tube  at  a  remote
 location.   Only the measurement of the stack diameter, and the measurement
 of  the   velocity pressures and gas temperatures need be done on the  plat-
 form.   Generally, about  one half the time involved in a Method 2 traverse
 can be spent  away from the platform.

 SLIDE 6-7

                                       This is a photograph of several  in-
                                       spectors  preparing  to make  a  gas
                                       temperaturfe  measurement at a 4 inch
                                       diameter  port on the  duct  leading
                                       from the induced draft fan.  At this
                                       location,   the  static  pressure  is
                                       between  one half and one inch posi-
                                       tive  pressure.    Even at  this  low
                                       pressure,   a substantial quantity of
                                       the  gas  can escape from  the  port
                                       into  the breathing zone of the peo-
                                       ple.   The cloud  of gas is visible in
                                       the left center  of the slide.

     These  large  diameter ports should be avoided,   especially  when  the
static pressure of the gas is positive.   The port should be one half  to  one
inch in diameter to minimize the flow rate of gas through the  port.    Only
ports with good ventilation should be used in any case.   Before opening  the
port,  the inspector should put on the appropriate respirator.

SLIDE 6-8
                                     86

-------
SLIDE 6-8
                                       This  is   the  discharge  duct  from   a
                                       medium sized   fabric  filter.   The
                                       duct is horizontal  and is  pointed  at
                                       the platform surrounding an adjacent
                                       fabric filter.   Some  of the   parti-
                                       culate matter  handled  by the  unit
                                       shown  in the  slide is highly toxic.
                                       If  there were a sudden  bag failure,
                                       there would be undesirable levels  of
                                       this  material in the  area where  an
                                       inspector might be.

                                       It  is very common for the baghouse
                                       discharge  to   be  very  low  to the
                                       ground with either  a  horizontal  or
                                       downward    orientation.     In  other
                                       words, many stacks do not point up!
                                       Sudden malfunctions of air pollution
                                       control devices occassionally happen.

     The  inspector must be aware of all the pollution control  system  dis-
charge  points  and all process vents.   It is necessary to  be  constantly
aware of the best way to leave the area rapidly  and it is advisable  to have
a respirator available at all times.


                                       This  photograph shows a modern as-
                                       phalt  concrete plant.  The  "stack"
                                       for the baghouse is the  rectangular
                                       vertical   duct on the  right side  of
                                       the  baghouse.   It is apparent that
                                       the  inspector must walk right  next
                                       to the discharge point (at the  same
                                       elevation  as  his or her feet) while
                                       going  to check the operation of the
                                       diaphragm  valves and  the   condition
                                       of  the top hatches.  A cross  wind
                                       would  easily  carry the  exhaust  to
                                       the breathing  zone of  the  inspector.

     Unfortunately,  emissions  from asphalt concrete plants  do not  have   a
high opacity even when the rate of emission is above  the regulatory   limit.
Therefore,  inspectors  could underestimate the  quantity of material  they
are being exposed to.

     A baghouse does not remove any gases and vapors!   Many  asphalt plants
(and  other facilities) have moderate concentrations  of sulfur  dioxide  and
other contaminants which easily pass through the baghouse.
                                    87

-------
SLIDE 6-10
                                       This  is a view of a top of a cupola
                                       at a foundry.    It is very  abnormal
                                       for  the  top   to be  open  and  the
                                       emissions  to  be escaping to the at-
                                       mosphere without any control at all.

                                       The upset at this plant occurred due
                                       to failure of  the induced draft  fan
                                       in the air pollution control system.
                                       The  emissions  include  particulate
                                       matter,  carbon monoxide, sulfur di-
                                       oxide,  and  partially combusted or-
                                       ganic vapors.

     It  is very probable that the inspector would be on site  during  this
time  in response to the malfunction report called in by the plant  person-
nel.  The area fumigated by the plume from the upset  process equipment must
be avoided.  Sudden changes in the wind direction can result in exposure to
the highly contaminated plume.
SLIDE 6-11

                                       This  is  a photograph of  the  same
                                       plant  shown in the above slide.  It
                                       was  taken approximately 30  seconds
                                       after the above picture.   The plume
                                       from  the cupola discharge has  been
                                       caught  in a downdraft and begun  to
                                       fumigate  the  area where the  plant
                                       environmental  manager and  the  in-
                                       spector  were located.   The picture
                                       was taken from a sheltered area  out
                                       of the direct path of the plume.

                                       Inspectors should always be aware of
                                       the  location  of the  plume  during
                                       such  periods and should avoid areas
                                       where  they might be trapped as  the
                                       plume passes.

    Inspectors  should always be aware of the best means to escape an  area
which  is suddenly in the path of the plume.   It may be impossible to  see
due  to the irritating properties of many pollutants.     The inspector may
experience  difficulty  in breathing.   The potential problems  related  to
falls  from  elevated surfaces (discussed in Lecture #2) become  even  more
serious under such conditions.
                                     88

-------
                                       This  appears  to  be  an  innocuous
                                       barrel  of solids directly below the
                                       hopper  of a baghouse.   A  gust  of
                                       wind can entrain a cloud of the dust
                                       and  blow it right into the face  of
                                       an  inspector.  It is common for the
                                       composition of such dusts to be   1%
                                       to 5%, by weight, toxic metals, such
                                       as lead cadmium and/or zinc.
 SLIDE 6-13
                                       This  is what a manufacturing opera-
                                       tion will look like when the  fabric
                                       filter (or other control system) has
                                       failed. Due to the poor ventilation,
                                       the  concentration  of  contaminants
                                       can  increase rapidly.   It will  be
                                       necessary  to  wear a respirator  in
                                       areas  which usually do not  require
                                       respirators.   The  inspector should
                                       make every effort to  minimize  the
                                       time he or she  spends in the affec-
                                       ted area.
Source: National Audiovisuals Center
                                     89

-------
SLIDE 6-14
                                       There  are moderately heavy deposits
                                       on the floor in this portion of  the
                                       plant.  Walking through this area to
                                       reach  the air pollution control de-
                                       vice  will  stir up  this  material.
                                       The  inspector should  usually  wear
                                       the  same type of respirator as  the
                                       personnel  working in this area  are
                                       using.   This area should be avoided
                                       if  there is an alternate  route  to
                                       the collector.
Source: National Audiovisuals Center
SLIDE 6-15

                                       High  concentrations of toxic   chem-
                                       cials  and asphyxiants can occur   in
                                       any "partially confined area".  This
    "PARTIALLY" CONFINED AREAS     is an area outside of any  equipment
                                       where  there  is poor air  movement.
                                       Fugitive leaks of pollutant gas from
                                       the air pollution control system  can
                                       result in very undesirable levels of
                                       the pollutants.   These areas  should
                                       be avoided if at all possible.     If
                                       it  is necessary to go through  these
                                       areas,   some  kind  of   protective
                                       equipment is often necessary.

     There  are numerous partially confined areas around  control  devices.
Not  only can the trapped pollutants cause acute respiratory problems,   but
also  the  inspector is more susceptible to physical injuries  because  the
exposure may cause symptoms such as lightheadedness which sometimes accom-
pany the exposure.

     The  problems with partially confined areas are most severe  when  the
collector  is under positive pressure.    Since the pressure in the unit  and
ductwork is above the pressure of the outside air,  any leak can result   in
high concentrations of pollutants in the immediate vicinity of the pollution
control system components.
                                     90

-------
SLIDE 6-16

                                       This is a  side view of  the  roof of a
                                       precipitator.    There is a  structure
                                       immediately  above the   precipitator
                                       which  restricts natural ventilation
                                       on the roof.   The unit  is under pos-
                                       itive  pressure and there are  leaks
                                       up into the roof area.

                                       In  some cases,  it is  necessary  to
                                       spend  up   to several hours  on  the
                                       roof of precipitators like  this,  to
                                       check  rapper  sequence  and  inten-
                                       sity.   Obviously a respirator would
                                       be necessary.
     Areas like this are prone to pollutant build-up when the wind  is calm.
It  is  important to be especially cautious on these days.   The  types  of
gases  which are common on electrostatic precipitator roofs include  sulfur
dioxide,  nitrogen oxides,  carbon monoxide,  and ozone.   Ozone is generated
by  ultraviolet  photolysis of molecular oxygen by  the corona on  the  pre-
cipitator wires.   The gas streams normally have an oxygen content   between
3%  and 10%.   For this reason,  it is also possible to  encounter an oxygen
de-ficient  atmosphere  (defined as < 19.5% oxygen) in  partially  confined
areas on the precipitator roof.
SLIDE 6-17

                                       This  slide shows the lower  portion
                                       of  one  collection plate rapper  of
                                       the unit shown previously.  There is
                                       an  obvious leak around  the  rapper
                                       seal.    This  is the main source  of
                                       the pollutant laden gas entering the
                                       partially confined area of the roof.

                                       It  is usually not possible  to  see
                                       these   leaks.  In  this case  ,  the
                                       moisture in the leaking gas  conden-
                                       sed rapidly,  marking the location of
                                       the leaks.
     It  is  difficult  to find and eliminate all of the leaks on  a  large
electrostatic  precipitator.    Some have a roof area which is close to  the
size of a football field.    There can be several hundred plate rappers  (as
shown  in  this  slide)  and large numbers of discharge  electrodes  and  gas
distribution screen rappers.    Access hatches on the precipitator roof  are
also  potential leak sites.   It should be assumed that leaks exist on  all
Precipitators under positive pressure.

                                     91

-------
SLIDE 6-18
                                       This  is a view looking down on  the
                                       roofs of two precipitators  which are
                                       in  an arrowhead  arrangement.    The
                                       stack  is in the upper left of   this
                                       slide.   The  white  structures  are
                                       weather enclosures over the roofs of
                                       the units.   In colder climates,  the
                                       weather  enclosures facilitate  main-
                                       tenance.   Even with the ventilation
                                       fan,  common in such enclosures,   it
                                       is possible to find high concentra-
                                       tions  of  pollutants  within  these
                                       structures.

     The  inspector  should wear the same type of respirator used  by  plant
personnel  in these areas.   It should be noted that these  enclosures  are
generally  desirable in that precipitator maintenance and precipitator long
term performance are enhanced.    They should not be discouraged solely  be-
cause  of some possible discomfort to the inspector.   There may be a   need
to measure the pollutant and oxygen concentrations prior to entry.  If the
inspector does not have the necessary safety equipment to enter this  area,
then the inspection must be abbreviated.
SLIDE 6-19
                                       This  is a picture inside a  weather
                                       enclosure  around the hoppers of  an
                                       electrostatic  precipitator.   Pollu-
                                       tant  laden  gas  may  leak  through
                                       the access hatches and weld gaps in
                                       the  hoppers leading to high  pollu-
                                       tant  concentrations  in this  area.
                                       Again,  it is necessary to test  the
                                       oxygen  level and the pollutant con-
                                       centration prior to entry.

                                       There is rarely a good reason for an
                                       inspector  to enter  the  enclosures
                                       around   hoppers  of  precipitators
                                       under positive pressure.  Checks for
                                       air infiltration are necessary  only
                                       on  negative  pressure  units.   The
                                       only  other  items of  interest  are
                                       provisions    to   prevent    solids
                                       overflow in the hoppers.   These can
                                       be  seen from the access door to the
                                       enclosure;  it  is not necessary  to
                                       enter.
                                     92

-------
SLIDE 6-20
Source: National Audiovisuals Center
This  is a multiple compartment bag-
house under positive pressure.   The
walkway between the compartments can
have very high pollutant  concentra-
tions  and low oxygen levels if  the
access doors, shell, or ducts leak.

Some of these walkways are like tun-
nels or large canyons.  The ventila-
tion  on a still day can be negligi-
ble.   It is advisable to avoid wal-
king  through  this area  unless  a
respirator is used.
     Unfortunately, this is where the differential pressure gauges for each
compartment are located.   Because it is necessary to observe the  pressure
drop for each compartment during the filtering mode and during cleaning,  an
inspector could spend a considerable amount of time in this area.

     If there are any symptoms of problems,  the inspector may need to look
into (not go into) one of the compartments.  To do this the plant personnel
must  isolate  the compartment and then open the hatch.   Since almost all
dampers leak,  this can result in some flow of pollutant laden gas into the
walkway area.   The inspector must have the appropriate respirator for  the
type  of  particulate matter and gas present.   If the flow of gas out  the
hatch is too rapid, shut the hatch immediately.
SLIDE 6-21
                                       This  is a close-up view of a  walk-
                                       way  between compartments of a large
                                       baghouse.   This particular unit   is
                                       under negative pressure.  Therefore,
                                       there  is less risk from accumulated
                                       pollutants  and  oxygen  deficiency.
                                       Nevertheless,  all  areas with  poor
                                       natural  ventilation should  be  ap-
                                       proached cautiously.
                                    93

-------
SLIDE 6-22

                                       The  fan shown in the slide serves a
                                       large venturi scrubber.   It is below
                                       the scrubber and surrounded on three
                                       sides by building walls.   The static
                                       pressure  of the duct  leading  from
                                       the fan to the stack is  under a low,
                                       but nevertheless significant,  posi-
                                       tive pressure.   A gap in the isola-
                                       tion  sleeve or a hole in this  duct
                                       could  result in high concentrations
                                       of the pollutants contained in the
                                       gas    stream   escaping   to    the
                                       inspector's breathing level.

                                       All fan houses or partially enclosed
                                       areas  surrounding fans  must be  ap-
                                       proached cautiously.
SLIDE 6-23
                                       This is a close-up photograph of the
                                       isolation  sleeve on  the  discharge
                                       side  of the fan shown in the  slide
                                       above.   There  are a number of gaps
                                       wrhich are leaking high velocity  gas
                                       into the area around the fan.
                                     94

-------
SLIDE 6-24
                                       This  is  the scrubber  control   cab-
                                       inet  which is located  less  than   3
                                       feet from the the cracked  isolation
                                       sleeve  (see last two  slides).    An
                                       inspector  trying  to determine  the
                                       operating conditions of the scrubber
                                       could  be  fumigated with   toxic  or
                                       oxygen deficient gases.
SLIDE 6-25
                                       This  is another  isolation  sleeve  of
                                       a fan.    One half of the  sleeve  has
                                       been  removed  for reasons  that  are
                                       not  known.    A similar  condition can
                                       result  in  extremely high levels  of
                                       gases  in the area around  the   fan.
                                       This  type   of condition  is  not  as
                                       uncommon as it should be.
                                     95

-------
SLIDE 6-26
                                       This  is the discharge side  of  a  fan
                                       downstream of a  baghouse.    A  cloth
                                       has been stretched  over the  fan dis-
                                       charge   presumably   to  reducethe
                                       amount of the solids from  accumulat-
                                       ing around the fan.   The  area  imme-
                                       diately surrounding the fan  had A to
                                       12  inches of accumulation.   It   is
                                       not  unusual to  find high  emissions
                                       from  the  discharge  of  a   control
                                       system baghouse. What is  unusual is
                                       the  futile effort  to keep the  mate-
                                       rial in the fan.

                                       This  slide  illustrates  that  high
                                       levels of pollutants can exist  near
                                       fans  which  discharge  into poorly
                                       ventilated areas.
SLIDE 6-27
                                       A continuous emission monitor mounted
                                       on  a  stack of a coal-fired  utility
                                       boiler is shown in this  slide.    The
                                       unit  is between the stack liner  and
                                       the outer shell.   The cylinders with
                                       calibration  gas are stored just  out
                                       of view to the left.  If these cylin-
                                       ders  leak,  it  is possible to  have
                                       undesirable concentrations of  sulfur
                                       dioxide  and  nitrogen oxides in  the
                                       area around the transmissometer.

                                       Transmissometers mounted on positive
                                       pressure  ducts can have high pollu-
                                       tant  levels around the unit due  to
                                       fugitive leaks.
                                      96

-------
SLIDE 6-28
  Source: EPA Air Pollution

         Training Institute
                                       This  is a  drawing of a  floating roof
                                       storage tank  for hydrocarbons.  High
                                       concentrations of organic  vapors can
                                       exist on the  top of the roof because
                                       of  leaks  through the  seals.   The
                                       vapor concentration should be  meas-
                                       ured  before  the inspector enters  to
                                       check the  seals.

                                       The external  walls of the  tank block
                                       off the wind  resulting  in  poor  ven-
                                       tilation   on  the roof surface.   The
                                       highest  concentrations of  organic
                                       vapors occur  in precisely  the  areas
                                       that  the  inspectors check the  seal
                                       condition.
SLIDE 6-29
                                       This   is a photograph of a  building
                                       demolition site.   While  attempting
                                       to  get  samples of  the  insulation
                                       material in the area,  the inspector
                                       could  enter a sheltered area  where
                                       there  is  a high  concentration  of
                                       asbestos fibers.

                                       In  addition to the obvious  inhala-
                                       tion   hazards there are a number  of
                                       physical  hazards.    These  include
                                       floors which can not support the in-
                                       spector's weight and falling bricks.
                                     97

-------
 SLIDE 6-30
                                        This   is   a  view  of  the inside of  a
                                        fabric filter.    A REGULATORY AGENCY
                                        INSPECTOR  SHOULD  NEVER ENTER AN  AIR
                                        POLLUTION    CONTROL  DEVICE.   FATAL
                                        INJURIES   ARE POSSIBLE INSIDE  THESE
                                        DEVICES.

                                        These  devices should be entered only
                                        by individuals trained and  equipped
                                        for confined area entry.   They must
                                        be specifically trained and equipped
                                        to  survive  the  potential  hazards
                                        inside    air   pollution    control
                                        devices.   These hazards include  but
                                        are not limited to:

                                           1,  Asphyxiants
                                           2.  Toxic Gases
                                           3.  Toxic Particulate
                                           A.  Hot, Free Flowing Solids
                                           5.  Oxygen Deficiency
                                           6.  High Voltage
                                           7.  Rotating Equipment

      It  is  more difficult to rescue an individual overcome inside an  air
 pollution control device than it is to  rescue persons from sewers and other
 equally  dangerous locations.   This is because most units have very  small
 hatches, many internal components that could  snag rescue  ropes,   and  most
 devices are located in high and remote parts of the plants.

      A  QUALIFIED  AGENCY INSPECTOR CAN EFFECTIVELY ACCOMPLISH ALL  OF  THE
 INSPECTION  REQUIREMENTS WITHOUT ENTERING THE CONTROL  DEVICE.   INSPECTORS
 SHOULD REFUSE TO ENTER ANY COLLECTOR EVEN WHEN ENCOURAGED TO DO SO BY PLANT
 PERSONNEL.   PLANT  PERSONNEL SHOULD ABSOLUTELY REFUSE PERMISSION  FOR  THE
 INSPECTOR TO ENTER THE CONTROL DEVICE.

      When  an inspector is overcome inside a collector it is probable  that
 one   or  more of the plant personnel will attempt a  rescue.   This  places
 these individuals at a very substantial risk.

     This issue is stressed because the author has noted a wide spread lack
 of respect for the hazards inside these collectors despite the accident  and
 "near  miss" history.   Some manuals even imply that  internal  inspections
 should  be done routinely.   Others place great faith in the conditions   of
 the  collectors.   These   individuals do not suspect  that   the   isolation
 dampers on many collectors leak severely,  rendering an "isolated" compart-
ment  as  dangerous as a compartment which is on line.    Some  people also
 place too much faith in the lock out systems  of the collectors.   For  all of
 these  reasons  there is a need to stress the potential hazards that   exist
inside  air pollution control devices.   REGULATORY AGENCY INSPECTORS NEED
NOT AND SHOULD NOT ENTER THESE DEVICES.
                                     98

-------
SLIDE 6-31

                                       Recognizing areas that  are  potential
                                       sites  for   exposure has   been   the
                                       first  topic presented  in this   lec-
                                       ture because avoiding hazards is the
                                       best way to minimize  risk.   Many of
                                       the  materials   inhaled during   the
                                       inspection have  poor  warning proper-
       MOST CONTAMINANTS          ties.   In  other words,  the person
                HAVE                  raay nave no physical  sensation   that
    POOR WARNING PROPERTIES       thei?  ar.e hi§h  levels  of pollutants
                                       in the air.

                                       For example,  the inhalation of  dust
                                       and fume rarely  causes  any  immediate
                                       physical  discomfort  or impairment.
                                       For  this reason it is  possible   for
                                       undesirable quantities  of toxic  mat-
                                       erials such as lead,  arsenic and as-
                                       bestos to reach  the lungs where  they
                                       can be slowly absorbed  by the  blood
                                       and attack  organs such as  the liver
                                       and kidney.

     The  chemical and physical asphyxiants are another group  of   chemicals
with very poor warning characteristics.   Chemical asphyxiants such as  car-
bon  monoxide  and hydrogen sulfide can occur at  life   threatening  levels
without  any odor or taste perception.    The most common physical  asphyxi-
ant, carbon dioxide,  also does not have any odor.

     Most  organic compounds and nitrogen dioxide are not very soluble   and
can penetrate deep into the lower  lung.   The initial symptoms of  exposure
are non-specific and may not be recognized by the inspector  who is preoccu-
pied in conversation with plant personnel or in the  inspection activities.
These symptoms include dizziness,   drowsiness,   headache, light-headedness,
and  nausea.   Acute exposure can  result in pulmonary edema  hours  after the
exposure.

     The  chemicals which have the best warning properties are those  which
are partially soluble in body fluids.   The low taste and odor  thesholds  of
compounds such as sulfur dioxide,  ammonia and chlorine  are due primarily to
the  solubility  of these materials.    Most individuals (but not all)   will
Quickly leave an area with a high  concentration of such chemicals.  Failure
to do so, however, can lead to severe cardio-pulmonary  problems.

     Inspectors  should review the plant files to determine  which  chemicals
might  be encountered during the inspection.    The warning   properties   of
these  materials  should be reviewed so that everyone is aware of  the   con-
sequences of exposure to the toxic materials.    One  very useful document  to
assist  the inspectors is the NIOSH/OSHA Pocket Guide to Chemical  Hazards.
"The  field  manual is available from the Superintendent  of  Documents,   U.S.
Government  Printing Office,  Washington D.C.  20402.  Each inspector should
have  a copy of this document and  any other reference   materials   necessary
    the types of chemicals which may be encountered.

                                    99

-------
              BERYLLIUM

Route of Entry — Inhalation of Dust and Fume
Symptoms    — Intense, Brief Exposure May Result in
             Nonproductive Cough, Low Grade Fever,
             Chest Pains, and Shortness of Breath
Consequences — Acute Exposure Can Result in Chemical
             Pneumonia with Pulmonary Edema Several
             Hours After Exposure
SLIDE 6-32

                                         The  next  series of slides discusses
                                         several  of   the  common   chemicals
                                         which  can  exist in  the  partially
                                         confined areas  and surrounding areas
                                         of  air  pollution control  systems.
                                         This  section demonstrates  the   im-
                                         portance   of the use of  respirators
                                         and  avoidance  of unnecessary expos-
                                         ures to the  chemicals.

                                         The warning  properties and  possible
                                         effects  of  beryllium are listed   in
                                         this slide.   This is one of the most
                                         toxic chemicals which may be inhaled
                                         by a field inspector.  Like a number
                                         of  other  materials,  this can cause
                                         edema several hours after  exposure.
                                         The initial  symptoms of exposure  are
                                         not very dramatic.

     Due  to  the poor warning  properties of beryllium  and the very  serious
consequences  of exposure,  field  inspectors must  plan  to use personal  pro-
tective  equipment.   They  should  not wait for  the  initial  symptoms   of
exposure  to   this  material.   All areas of potential exposure  should   be
discussed   with  the plant personnel before the inspection  and  all  areas
which are not relevant to the  inspection should be  avoided.
SLIDE 6-33
   Route of Entry

   Symptoms
                  CADMIUM
             — Inhalation of Dust and Fume
             — Acute Exposure May Occur Without
               Immediate Symptoms

   Consequences — Pulmonary Edema
Cadmium   is  another  toxic     part-
iculate   material with little  in the
way  of   initial  warning  symptoms.
The consequences of an acute   expos-
ure  include  a very serious respira-
tory condition.
                                       100

-------
 SLIDE 6-34
Route of Entry

Symptoms
           HYDROGEN SULFIDE

          — Inhalation of Gas

          — At High Concentrations There Is No Odor
Consequences —  Chemical Pneumonia May Develop Several
             Hours After Exposure
                                        At low concentrations, hydrogen sul-
                                        fide is an eye irritant and  it  has a
                                        very  disagreeable rotten  eggs   type
                                        odor.   If these symptoms  are noted,
                                        the   inspector  should  leave    the
                                        affected  area  of the  plant.    Ex-
                                        posure  to higher concentrations  of
                                        hydrogen sulfide can occur in   areas
                                        close to the point where these  symp-
                                        toms were first noted.   At  moderate
                                        to  high  concentrations,    hydrogen
                                        sulfide   is  an  extremely   deadly
                                        chemical: at high concentrations the
                                        gas quickly overcomes the  olfactory
                                        senses.

     It is possible to walk into a confined or partially confined area with
toxic  concentrations of  hydrogen sulfide and be only briefly aware of  its
presence  before olfactory  fatigue overcomes your senses and you  think  the
problem  has  gone  away.    Brief exposure to such conditions can  lead  to
pulmonary  edema  and other serious respiratory problems in 6 to  12   hours
after the exposure.  The  exposure can also result in immediate death.

    A  large  number  of  the industrial processes frequently  inspected  by
regulatory agencies handle  high concentrations of this gas.   These include
sour gas wells,  petroleum  refineries,   and petrochemical chemical  plants.
It  can also be found in  some unlikely locations such as downstream of cup-
olas.  Pockets of the chemical can occur in partially confined areas around
the sources and it can even occur in depressions along the ground.
SLIDE 6-35
Route of Entry

Symptoms
           NITROGEN OXIDES
          — Inhalation of Gas
          — Irtttial Symptoms Include Cough, Chills,
            Fever. Headache, Nausea

Consequences — Acute Pulmonary Edema May Follow Five
            to TWelve Hours After Exposure
                                        During   the  exposure  to  nitrogen
                                        oxides  only mild bronchial  irrita-
                                        tion may be experienced.  Concentra-
                                        tions  of 100-150 ppm are  dangerous
                                        for periods of 30 to 60 minutes.

                                        Nitrogen oxides are generated in al-
                                        most all combustion processes. While
                                        they  do not have a distinctive odor
                                        it is sometimes possible to see  the
                                        orange color of nitrogen dioxide.
     Also,  nitrogen   oxides are often accompanied by sulfur dioxide   which
can be smelled and tasted  at low levels.   When there is the odor  of  sulfur
dioxide it is the possible that nitrogen dioxide is present.   Unfortunate-
ly nitrogen oxides can occur without the odor of sulfur dioxide.

     This  set of gases is one  example of the  nonsoluble  chemicals.    The
site  of attack is the deep lung and the consequences of acute exposure   is
aevere.   Typical effluent concentrations are 400 to 1000 ppm.   Concentra-
tions of 100 to 150 ppm are possible in partially confined areas.
                                     101

-------
SLIDE 6-36
 Route of Entry

 Symptoms

 Consequences
  ASBESTOS

Inhalation of Fibers

No Immediate Physical Symptoms

Asbestos is a Confirmed Carcinogen
Asbestos  is a  confirmed carcinogen.
Exposure   to   asbestos  fibers  can
occur while inspecting building  de-
molition sites.   There are no imme-
diate  physical   symptoms  following
the exposure to asbestos.

This  is one of the best  publicized
of the known or suspected carcinogen
compounds.  Other chemicals commonly
encountered include vinyl  chloride,
benzene, and halogenated organics.
SLIDE 6-37
              CHLORINE

Route of Entry — Inhalation

Symptoms    — Intense Irritation of Eyes, Nose, and Throat

Consequences — Respiratory Problems
                           Chlorine is one of a number of  chem-
                           icals which are partially soluble in
                           mucous membranes.   The initial site
                           of  attack includes the eyes,   nose,
                           and throat.   It has relatively good
                           warning properties.

                           Exposure  can occur due to an   acci-
                           dental  release from process  equip-
                           ment.   Inspectors must be aware  of
                           plant  warning sirens and know   what
                           to  do if a cloud of chlorine is ap-
                           proaching their location.
     The  possibility of chlorine release is just one of  the reasons why it
is important that  plant personnel accompany the inspector at all times.  As
soon as there is a warning siren indicating a release in  the general vicin-
ity, everyone should  proceed to a safe area and check in  by  phone to a cen-
tral  location.    The wind socks or pennants flying from  the tops  of  some
process  equipment provide  a general indication of  the wind  direction*
Obviously,  it  is usually safest in the upwind direction of the  suspected
release area.  An  area engulfed by the charactristic yellow  cloud should be
avoided  while going  to a protected area.    Respirators  should be  carried
while   inspecting   areas  where  chlorine  releases   are   a  significant
possibility.
                                      102

-------
SLIDE 6-38
DETECTION AND MEASUREMENT
              OF
     INHALATION HAZARDS
There  are many methods and  instru-
ments  currently available  for  the
detection and measurement of inhala-
tion  hazards.   For the inspector's
purposes,  any method or  instrument
used  should be relatively  inexpen-
sive, lightweight and easy to trans-
port.   It  should also be simple to
use.
SLIDE 6-39
    • Personal Protection Badges
    • Detector Tubes
    • Combustible Gas Indiators
Keeping the above fact in mind,  this
discussion will center on three  ways
of  detecting  and/or measuring   air
contaminants:   personal  protection
badges, detector tubes, and combust-
ible gas analyzers.

The  personal protection badges   are
useful  mainly to warn the inspector
that he has encountered a high  con-
centration  of  the applicable  gas.
The  detector tubes can be  employed
for  both detection and  fairly   ac-
curate  measurement of most types of
pollutants.
     The  combustible  gas  analyzers  are  used   to  measure  the  explosion
potential  of  vapors  and thus are useful for  detecting  and  measuring  a
number of volatile organic compounds.
                                    103

-------
SLIDE 6-40
     PERSONAL PROTECTION
           BADGES
The  commercially available personal
protection  badges function  by  two
different  mechanisms.    One   type
gives a comparatively instant  indi-
cation of the presence of the appro-
priate gas by undergoing a change in
the color.   The other is worn for a
specified amount of time (e.g. 8-hour
shift  and  then is sent  to  a  lab
where  it is analyzed for adsorption
of  the pollutant). The second  type
is  much like the  radiation  badges
with  which  you  may  be  familiar.
We'll discuss only the first type at
length,  because  this type is  most
useful for the inspector for instan-
taneous   detection  of   inhalation
hazards.
SLIDE 6-41
 Leak-Tec
   VMrtWVtt* - * »«*
          :

   *     «
This  type  of passive dosimeter  or
personal  protection indicator is  a
badge  which has a piece of  reagent
impregnated filter paper (or  button
in  the  case  of CO  badges)  which
chemically reacts with the specified
gas causing the indicator to  change
color.   The color change provides a
warning  of excessive exposure to  a
toxic gas.
                                    104

-------
 SLIDE 6-42
   INSTANT READING BADGES AVAILABLE

  Toxic Substance    Critical Cone.    Color Change
  Ammonia           25ppm      Yellow to Blue
  Carbon Monoxide      SOppm      Tan to Black
  Chlorine            1ppm     White to Yellow
  Hydrazine           1ppm     White to Yellow
  Hydrogen Sulfide      5ppm     White to Brown
  Nitrogen Dioxide       ippm     White to Yellow
  Ozone             1ppm     White to Brown
The  types of  badges available  from
one  manufacturer  are listed in this
slide  along with  the critical  con-
centration of  the  specific gas which
affects the color  change.   The crit-
ical  concentration  is based on  the
time-weighted  average  (TWA)  for  8
hours  of exposure to the   gas.   In-
spectors  can  clip  these   badges  to
their  belts   to   warn them  if  high
concentrations of  these   gases  are
present.
SLIDE  6-43

                                        In   theory,    the  degree  of  color
                                        change    of   these  badges  can    be
                                        correlated with a particular concen-
                                        tration  of the gas over time.   This
                                        is shown in  this slide of the  manu-
                                        facturer's  color chart for the  am-
                                        monia badge.   The manufacturer, how-
                                        ever,    no   longer  supplies  these
                                        charts,   but   it  is useful to  note
                                        that the degree of color change  can
                                        be  used  to  estimate  the  relative
                                        concentration of the gas.  Of course,
                                        any  change   to blue on  this  badge
                                        would signal  the wearer to leave the
                                        area immediately.

     These badges  accumulate very low concentrations of gas over  time.  For
example:  if  a chlorine badge is exposed to 0.2  ppm for   several  days,   a
color  change  will   eventually result due to the  total   concentration  of
chlorine exposure.  This may result in the false  conclusion that  a 1 ppm of
high  concentration   of  chlorine was present in the  ambient air during  the
    of the color change.    As a result of this accumulation  characteristic
    the badges,  it is recommended that inspection personnel use  the badges
     one time.
                                     105

-------
 SLIDE 6-44
     BADGE         BLOCKING GASES
Ammonia         High Concentration of acid
                 gases such as: Sulfur Dioxide
                 Nitrogen Dioxide
                 Hydrogen Sulfide
Carbon           High Concentrations of
Monoxide         Nitrogen Dioxide temporarily
                 block reaction.
                 Temp<0°C
Chlorine          High Concentration of Carbon
                 Monoxide, Hydrogen Sulfide
                 & Hydrazine
Hydrazine        Ammonia
Hydrogen         No known gases or vapors
Sulfide           block the reaction
Nitrogen         High Concentrations of
Dioxide          Hydrogen Sulfide, Carbon
                Monoxide & Hydrazine
Ozone           High Concentrations of
                Hydrogen Sulfide, Carbon
                Monoxide & Hydrazine
                                 Before  making use  of these  badges,
                                 it   is essential to understand their
                                 limitations.    As this slide  shows,
                                 all    the   types  of  badges  except
                                 hydrogen sulfide have certain  gases
                                 which  "block" or prevent  the  color
                                 change reaction.
 SLIDE 6-45
 GAS
INTERFERENCES
REPEAT-
ABILITY
 Ammonia     Amines & other basic      90%
            gases or vapors
 Carbon      Hydrogen Sulfide         90%
 Monoxide     Tobacco Smoke
            Ammonia Turns Indicator
            Blue
 Chlorine      Hydrogen Chloride        95%
            Ozone. Nitrogen Dioxide
 Hydrazine     Primary Amines          90%
 Hydrogen     Gases & vapors contain-    90%
 Sulfide       ing reduced sulfur such as
            Mercaptan. Gases con-
            taining phosphorous
 Nitrogen      Chlorine, Ozone          95%
 Dioxide      Hydrogen Chloride
 Ozone       Hydrogen Chloride        95%
            Nitrogen Dioxide
            Chlorine
The   reagents on each type  of  badge
which  affect the  color   change   for
the  gas of  interest are sensitive to
one   or more other  gases.    This   is
termed  interference  and a list   of
interfering gases  for each  badge   is
shown in this slide.

Also  shown  in  this slide  is   the
repeatability   for  each  type    of
badge.
                                          106

-------
SLIDE 6-46
          EFFECTS OF WATER

        Water is necessary for the color
        change reaction; badge deteriorates
        after  3 to 5 days exposure to the
        atmosphere
        Sensitivity of reaction increases with
        increase in humidity
                                        Water has quite  a  significant effect
                                        on the indicators.    Their sensitiv-
                                        ity  increases as  the humidity.

                                        Dry   atmospheres   also  affect  the
                                        badges response.    The color changes
                                        that  the badges undergo require the
                                        presence of water.    When an indica-
                                        tor is exposed to  the ambient atmos-
                                        phere,  water that  is present in the
                                        paper begins to  evaporate;  the rate
                                        is dependent on  the temperature  and
                                        the humidity.    As  it evaporates, it
                                        removes some of  the the color change
                                        reagents along with it.

     Eventually  a  critical point is reached where the  amount of water  and
reagent  remaining   is  insufficient to cause a color change.    This  point
usually occurs with 3 to 5 days of exposure to the atmosphere.   Carbon mon-
oxide badges are an exception to this because they use  a  different  type  of
indicator material.
SLIDE 6-47
         OTHER CONSIDERATIONS
    • Temperature Range — 50° to 120°F
    • SneifLife—        Six months
    • storage —         Cool, dry place away
                    from direct sunlight
    • Reusable—        No
                                        Other  important considerations  are
                                        listed  on this slide.    It is clear
                                        that the badges are not  as  reliable
                                        under  cold conditions.    The  shelf
                                        life  should be  carefully  watched.
                                        Dispose of expired badges.   Storage
                                        during the six months should be in a
                                        cool,  dry  place  away  from  direct
                                        sunlight.

                                        Some  of the  indicators  (chlorine,
                                        nitrogen dioxide, ammonia,  and ozone
                                        appear  to "regenerate"  when removed
                                        from  the contaminated   environment.
                                        Badges  that  have  gone  through  a
                                        distinct   color   change   due   to
                                        exposure  should not be  reused  even
                                        if it has"regenerated" to the  orig-
                                        inal  color.   When  a color  change
                                        occurs a portion of the  reagents are
                                        used and thus the level  of sensitiv-
                                        ity probably decreases.
                                      107

-------
 SLIDE 6-48
         GAS INDICATOR OR
          DETECTOR TUBES
Gas  indicator  or  detector tubes of-
fer a more sophisticated system  for
detection  and  measurement of  gases
and vapors than the personal protec-
tion  indicators   discussed  in  the
last set of  slides.
SLIDE 6-49
                                      Detector  tubes  provide  a  general
                                      indication of concentration for more
                                      than  150 gases,  vapors,   and a few
                                      aerosols.
   Source: National Draeger,  Inc.
                                    108

-------
 SLIDE  6-50
                                       Although detector tubes are used  in
                                       a  variety of applications,  the air
                                       pollution  inspector is most  likely
                                       to  employ  them for  two  different
                                       purposes.  The first is the measure-
                                       ment  of  pollutants for  monitoring
                                       purposes.   This slide shows a  mea-
                                       surement  being taken to investigate
                                       a possible leak from process  equip-
                                       ment.
  Source: National Draeger, Inc,
SLIDE 6-51
                                       The second  use  of detector  tubes   is
                                       the    sampling    of     potentially
                                       hazardous   atmospheres   in   confined
                                       areas,  partially  confined areas,  and
                                       in   areas around   positive   pressure
                                       duct systems.   Sampling information
                                       can  then be used to make  decisions
                                       concerning  entry  to the  area   and
                                       selection of proper respiratory pro-
                                       tection.
   Source: National Draeger, Inc,
                                     109

-------
SLIDE 6-52
        DETECTOR TUBE SYSTEM
 • Pump
    Bellows
    Piston
 • Indicator Tube
The detector tube system consists of
two parts, the pump (usually bellows
or  piston)  and the indicator  tube
(appropriate  for  whatever gas   or
vapor is being sampled).
SLIDE 6-53
                                       The pump is used to draw a  measured
                                       volume  of  the air   to  be   sampled
                                       through the indicator  tube.    In  the
                                       case  of  the bellows  pump shown  in
                                       the  slide,  a  fixed  and  constant
                                       volume  of air is drawn through   the
                                       tube  each  time  the  bellows   are
                                       squeezed.   To  sample the  measured
                                       volume  of  air  appropriate   for a
                                       certain indicator tube,  the  pump is
                                       squeezed the number of timoc   speci-
                                       fied in the literature for each type
                                       of tube.
  Source:  National  Draeger,  Inc.
                                     110

-------
SLIDE 6-54
                                        The  indicator tube is a hermetically
                                        sealed   glass  tube  (the  ends  are
                                        broken  off immediately prior to use)
                                        containing a solid granular material
                                        impregnated  with  an  agent   which
                                        reacts  to a specific air contaminant
                                        as it is drawn through the tube.
  Source: National Draeger, Inc,
SLIDE 6-55
        TYPES OF INDICATOR TUBES
  1. Direct Reading Stainlength
  2. Color Comparison
  3. Color Matching
Based   on   the  method   used    to
interpret   the  gas  concentration,
there  are  three  major  types    of
indicator  tubes.   The first  is  the
stainlength tube where the length of
a   colored  stain   indicates   the
concentration  of  the  contaminant;
this  used  either a set  number   of
pump volumes or you count the  number
of  pump  volumes to produce   a   set
stainlength.
                                      Ill

-------
 SLIDE 6-
 «»»**»**<*«*
 ,«••*
-------
 SLIDE 6-58
       INSTRUMENT LIMITATIONS
 As    was  true  with  the   personal
 protection   indicators,    it    is
 important    to    understand    the
 limitations of the instruments.

 A critical limitation is the quality
 control      exercised     by     the
 manufacturer  of the indicator tubes
 and  pumps.  NIOSH currently conducts
 a certification program designed  to
 help  insure  that  detector   tube
 sampling   systems.   conform   with
 established  performance  specifica-
 tions.    The  manufacturer's  submit
 test batches of tubes for certifica-
 tion and  at  the  same  time  must
 submit   a  quality control plan  for
 the   manufacture  of  the  same.   A
 manufacturer's  tubes are  certified
 by specific type;   the certification
 includes use with the pump unit.
SLIDE 6-59
          ACCURACY
  • Certification indicates ± 25%
  • Tube calibration can be user verified
  • Pump should be calibrated with
    respect to volume and flow rata
The NIOSH certification  on  a  type of
indicator  tube  signifies  that   if
they are used according  to  manufact-
urer's directions, they  will  produce
readings  that  are within  plus   or
minus 25% of the true  concentration
at 1,2,  and 5 times the test stand-
ard (usually the TLV).

Their  accuracy can be   verified   by
sampling  a  contaminant source   of
known  concentration prodecures   for
this are described in several of  the
references.
     The pump itself can and should be user  calibrated  at  regular intervals
with respect to both volume (delivered) and  flow  rate.   Several references
also describe procedures for this.
                                     113

-------
SLIDE  6-60

  OTHER CONSIDERATIONS IN THE USE OF
           DETECTOR TUBES
                           and
 • Shelf life and storage
 • Interfering gases
 • Color comparison and matching accuracy
 • Non-interchangeability of different manufacturers' tubes
   and pumps
                    Other    .Limitations  which  must   be
                    considered are listed in this  slide.
                    Extremely  high or low  temperatures
                    will   affect  measurement  accuracy.
                    This is due to its influence on both
                    the  volume of air sampled  and   the
                    kinetics of the reaction occuring in
                    the detector tube.
SLIDE 6-61
      TEMPERATURE EFFECTS ON
      INDICATOR TUBE SHELF LIFE
         °F        Shelf Life
         75
         120
         175
         210
         255
         300
2 years
 1 year
 weeks
 1 week
 3 days
 1day
Temperature  also greatly influences
the   shelf  life of  detector  tubes.
Under normal  conditions the shelf of
most  tubes is 2 years.   But as  is
shown in   this  slide,  storage  at
elevated  temperatures  can  greatly
decrease the  shelf life.   Thus,  it
is    important  that  the  tubes  be
carefully   stored   to   insure   a
reasonable  temperature;  they should
never be left in a place such as the
trunk  of  the   inspector's   car.
Refridgeration,     in   fact,    can
increase  shelf life,  but the tubes
must  be  temperature   equilibrated
before  use.    Tubes should also not
be stored in  direct sunlight.

-------
SLIDE 6-62
OTHER CONSIDERATIONS IN THE USE OF
          DETECTOR TUBES
• Temperature effects on pump volume and reagent re-
 action kinetics
• Shelf life and storage
• Interfering gases
• Color comparison and matching accuracy
• Non-interchangeability of different manufacturers' tubes
 and pumps
Similar   to the personal   protection
badges,   many of the detector   tubes
are  not   totally specific  for  one
contaminant     and    there     are
interfering  gases and vapors   which
must    be    considered.       These
interferences  can  be  negative  be
additive   and  are usually noted  in
the manufacturer's literature.

There can also be problems with  the
color  comparison or matching aspect
of  reading  the  tubes.   Different
lighting   can change the look   of  a
color chart or color standard.    The
color matching charts themselves can
fade  with time and color  blindness
will obviously hinder comparisons.

Finally,   indicator  tubes and  pumps
from different manufacturer's should
never  be  interchanged  because  of
differences in pump suction  proper-
ties and  flow rates.
                                      115

-------
SLIDE 6-f>3
   COMBUSTIBLE GAS INDICATOR
            (SNIFFER)
A  combustible gas indicator is used
to detect and/or measure combustible
gases and vapors in the  atmosphere.
This section covers one type of com-
bustible  gas indicator,  the "snif-
fer", which used catalytic combustion
to  measure and read out in  percent
of  the Lower Explosive Limit  (LEL)
for the gas being tested.
SLIDE 6-64
                                       For the agency inspector,   this  in-
                                       strument has basically the same type
                                       of uses as the detector tubes  except
                                       that  it  detects  only  combustible
                                       gases and does not  measure low  con-
                                       centrtion levels as well.

                                       It can be used effectively for  sim-
                                       pie  screening  of   combustible  VOC
                                       leak sources.    This slide shows  an
                                       inspector  sampling at a bulk   gaso-
                                       line  terminal using the Century OVA
                                       a  more  sophisticated  combustible
                                       gas  analyzer  than  we will  discuss.

                                       The "sniffer"  can be used  for   test-
                                       ing  confined,  partially   confined,
                                       and  any  other suspicious area  for
                                       the presence of combustible gases.
                                    116

-------
SLIDE 6-65
                                       This  is a  photograph of a  combust-
                                       ible  gas   indicator.   It uses  the
                                       catalytic   combustion  principle  of
                                       operation.    The  squeeze bulb on the
                                       right  draws  an   atmospheric  sample
                                       (mixture of air and  combustible gas)
                                       into the sample chamber.  Here it is
                                       brought  into contact  with  a  hot
                                       platinum wire (filament) where rapid
                                       oxidation of  the  gas with the oxygen
                                       in the air  occurs.    This raises the
                                       temperature  of the  wire causing  an
                                       increase  in  its  electrical  resist-
                                       ance.    The   change  in  resistance
                                       activates the readout meter.

     The instrument is designed so an increase in  the amount of combustible
gas  causes  a  proportional  increase in the resistance of  the  platinum
filament  and  thus  the  amount of combustible  gas present  is  directly
indicated on the meter.

     The  instrument  also has another chamber which houses  a  "reference"
filament.   This compensates for the variable condition  under which it must
operate, e.g., minor voltage fluctuations and changes in temperature.

SLIDE 6-66
        PREOPERATIONAL CHECK

  1 •  Zero mechanically
  2.  Turn on/Zero
  3.  Purge
  *  Apply known calibration gas
  5.  Check for appropriate meter response based on gas
    calibration curve
  6  Punje
  7.  Turn off
                                       This  slide summarizes  the   preoper-
                                       ational  check  (or  simple one  point
                                       calibration) of the instrument shown
                                       above.  Other combustible gas indica-
                                       tors of similiar sophistication will
                                       use comparable  procedures.

                                       The  meter  is   mechanically  zeroed
                                       using the screw at  the  center bottom
                                       of  the meter.    The unit   is  then
                                       turned  on  and the meter   rezeroed
                                       electrically using  the  on/off  knob.
                                       To purge, squeeze the aspirator bulb
                                       several times.

     A  calibration  gas  of known concentration is applied to  the  inlet
Opposite  the aspirator bulb connection) and the bulb is  squeezed  three to
^°ur times.   Calibration gases can be obtained in cylinders,  made using a
&as  calibration kit,  or made using methods described in  a number   of  the
Deferences listed in the Appendix.  The instrument response is then checked
^ased  on the appropriate  gas calibration curve.   Finally,   the   unit  is
Purged again and then turned off until ready for use.
                                     117

-------
SLIDE 6-67
  58
IM
N
H
It
»
90
«
JO
a
u
0









f
/







/







/
/







/







/
'M(
N





j
/

'





)TE: L.E.L.
rPA Bui. Mo.





















Is 5.0%
32SM










          It  21 B  « JO


            1 LtL C«    UETH
                       H  10
 M  N  UN


.IN MR
                                       The  unit  readout  scale in in per-
                                       cent  of  the LEL from 0%  to  100%.
                                       The  LEL is the leanest mixture of a
                                       gas  which  will burn  (or  explode)
                                       when ignited.  This gives an instant
                                       indication  of  danger of  explosion
                                       of  an atmosphere,  it does not  in-
                                       dicate   whether   or  not   it   is
                                       dangerous  with regard to  toxicity.
                                       Also,  when a gas sample  concentra-
                                       tion  exceeds  the  LEL,  the  meter
                                       pointer   generally  first  deflects
                                       rapidly  upscale and then toward  or
                                       below zero.
     The  instrument is factory calibrated on hexane.   When used to sample
other  gases it will read slightly higher or lower depending upon the  gas.
An  example  of  this is shown in this slide which is  the  gas  curve  for
methane.   A  methane gas concentration at 40% of the LEL (or 20% methance)
will  read 60% on the meter of a unit calibrated on  hexane.   Two  percent
methane-in-air  is a commonly used calibration gas and should based on  the
proceeding  discussion give the response of 60% on the meter.   Other gases
can be used for calibration using the appropriate gas curve (usually avail"
able with the unit) .

    Similarily,   these  curves  can  be  used  to  roughly  estimate   the
concentration in ppm of a known gas in the atmosphere,  by first converting
the  meter  reading in %LEL to %LEL of the known gas using the  curve,  and
then converting the %LEL of the gas to a percent-in-air using this formula*

          (%LEL of gas) x (LEL of gas) = % Gas-in-air
The  percent gas-in-air figure is then converted to ppm by
ten thousand.
                                                            multiplying
                                   118

-------
SLIDE 6-68
       OPERATION
    1. Purge
    2. Turn on/Electrically zero
    3. Sample atmosphere
    4. Note response on meter
    5. Purge
    6. Turn off
For   routine    operation   of   the
unit the steps  listed   in this slide
are  followed.    It  should first   be
purged  by  squeezing  the  aspirator
bulb  several   times.    Then  it   is
turned  on  and electrically  zeroed
using the on/off knob.

Then  it  is  ready  to  be  used   to
sample  the atmosphere in  question.
This  is accomplished   by  inserting
the  hose or probe into the area   to
be  tested  and squeezing  the bulb
several  times  (Allow  A squeezes  for
a  standard  5  foot  sampling   hose,
increase by 3 squeezes for each  ad-
ditional 5  feet).    Note the reading
on   the   meter when  the   needle
stabilizes  for  a few  moments   after
the last bulb squeeze.   After  taking
the reading, purge the unit in fresh
air until the needle returns to zero
and then turn it off.
SLIDE 6-69


   COMBUSTIBLE GAS INDICATOR
           LIMITATIONS
Because  there are so many  types  of
combustible  gas  indicators,   each
with slightly different  limitations,
the  following  section  will   only
cover  the  general  limitations  of
combustible gas indicators.   Before
using  any instrument of this  type,
the  inspector should carefully read
all  the  manufacturer's  literature
and  take note of the specific  con-
siderations for its use.

The slides that follow will  outline
items  which  should  be  considered
with  every  instrument  and  should
give  the  agency inspector  a  good
idea of what to be aware of in using
such an instrument.
                                    119

-------
SLIDE 6-70
   INTRINSIC SAFETY CONSIDERATIONS
 • Check instrument approval
 • Repair work that breaches intrinsic safety warrants re-
   certification
                                        Combustible gas analyzers use heated
                                        wires,  electronics,  flames and other
                                        sources of  ignition.   When they are
                                        immersed  in a test atmosphere, it is
                                        theoretically  possible  that   they
                                        could   ignite  an  explosion.   Con-
                                        sequently,    most   combustible  gas
                                        analyzers are constructed such  that
                                        ignition  is  highly  improbable  in
                                        certain atmospheres.   These in  in-
                                        struments  are then considered  "in-
                                        trinsically  safe" for use in  these
                                        atmospheres.   Each instrument should
                                        be  checked  to determine  for  what
                                        types of  atmospheres it is certified
                                        or approved.

     It  is  also  important to consult the operating  and  service  manual
before  troubleshooting  or  servicing so that the intrinsic  safety  built
into  the  detector will be maintained.   If any repair work  breaches  the
intrinsic  safety  of  the  instrument,   it   should  be  returned  to  the
manufacturer for  testing and recertification.
SLIDE 6-71
     LIMITATIONS OF SUITABILITY FOR
    CERTAIN GASES OR ATMOSPHERES
  • Hatogenated hydrocarbons cause filament poisoning
  • Condensible vapors cause fouling
  • Oxygen enriched atmosphere may cause flash back
  • Oxygen depleted atmospheres will cause a much
   decreased Instrument response
                                        Certain gases and/or  atmospheres can
                                        cause instrument  damage,   explosion,
                                        or inaccurate response.   Halogenated
                                        hydrocarbon  gases  or vapors produce
                                        thermal decomposition products which
                                        corrode  the  sensor  and   alter  its
                                        sensivity and integrity.  Condensible
                                        vapors foul the sensor.

                                        In   spite  of  the  flame-arresting
                                        system,  some instruments may  flash
                                        back  in  a pure  oxygen   or   oxygen-
                                        enriched   atmposhere.     Check  the
                                        instruction  for  instrument limita-
                                        tions PRIOR to use.

     Oxygen  depleted   atmospheres  pose  a  different   sort of   problem.
Instrument  response is almost always dependent on the presence  of  suffici-
ent oxygen to support  combustion.    Without it,  meter operation ie erratic
or  the respons for the combustible gas is less than the actual   concentra-
tion.  If an oxygen depleted atmosphere is suspected, detector tubes can be
used to make that determination,   before using the combustible gas   indica-
tor.  Other atmosphere-related limitations not listed in this slide include
(1) a decreased response to sulfur compounds such as hydrogen sulfide,  (2)
no  response to explosive dust atmospheres,  and,  as mentioned  previously,
(3) an erratic response to gas-enriched atmospheres.
                                      120

-------
 SLIDE 6-72
          OTHER CONSIDERATIONS

     Sensitivity to Gas
     Calibration Gas
     Zero Drift
     Temperature
     Dust and High Humidity
     Probe Length
     Position Sensitivity
     lnt*rchang«abiltty of Parts
                                        All    instruments   exhibit   "zero
                                        drift",  i.e.  they drift from "true
                                        zero"  as  the instrument  is  used.
                                        Thus frequent checks of the zero, in
                                        a CLEAN atmosphere are important.

                                        Temperature  will affect  instrument
                                        sensitivity   and   accuracy.    The
                                        LEL  of  most gases varies with  the
                                        temperature.   NO instrument  should
                                        be  used at extremes of  temperature
                                        unless  the temperature's effect  is
                                        knownn.  Dust and humidity also have
                                        an  effect;  therefore,  many models
                                        include  a  dust filter  and  drying
                                        agent.

     When  a  long  sampling   line  or  probe is needed  in  the  field,  the
instrument should be calibrated using  the same set up.    In the case of the
unit  shown  in  Slide 6-65 the user must remember  to   increase  the  bulb
squeezes  in  proportion to the line length.    This unit is  also  position
sensitive; it must always be kept upright while sampling.
      As   is true with the detector tube systems,  NEVER
 from one  type of combustible gas indicator to another.
                                                          interchange  parts
SLIDE 6-73
    •i
      s
IN
M
70
(0
SO
40
It
20
It









/








/








/


H
N




/



OTE: U.E.L. l*4.0*__
FPA Bui. No. 325M



/






/






/
'






V






X















          °e  10  a
                                       Finally,   the   user  must take  into
                                       account  the identity of the gas  he
                                       or   she   is   measuring   and   the
                                       instrument's  sensitivity  to   that
                                       gas.  It must be remembered that the
                                       instrument is calibrated on only one
                                       gas  at a time  and  it will  measure
                                       only  that  gas accurately.     This
                                       slide shows  that   a   unit  calibrat-
                                       ed  with hexane will   read   slightly
                                       lower when sampling hydrogen.  Inter-
                                       fering  gases   and  vapors  can  also
                                       change the readings.
     The  sensitivity of the particular  instrument must also be  considered
when measuring low concentrations of  toxic gases,   because many instruments
are not accurate at the lower end of  the scale.
                                    121

-------
Source: National Safety Council
SLIDF. 6-74
                                       The  next  portion  of  the  lecture
                                       concerns  the  selection and use  of
                                       respirators.  This is something that
                                       must  be  addressed before  starting
                                       the inspection.

                                       There  is a lot more to the use of a
                                       respirator than just slapping one on
                                       when the need arises.   Each  person
                                       should have a medical examination to
                                       confirm  that  he or she can  manage
                                       the additional stress caused by  the
                                       respirator.   Inspectors  should  be
                                       trained  on  the use and fitting  of
                                       each  style of respirator they  will
                                       use.   The training should also  in-
                                       clude  instructions concerning regu-
                                       lar  cleaning and inspection of  the
                                       unit.   There should be written pro-
                                       cedures covering all aspects of res-
                                       pirator selection and use.

     This lecture will provide only a brief introduction to this topic.   A
complete program concerning respirator selection and use requires  one half
to  three  days,  depending  on the types of units to be  used.   All  U.S.
Environmental  Protection Agency personnel engaged in field  activites  are
required  to have a minimum of 6 hours training on the selection and use of
respirators (see EPA Order 1440.3, July 24, 1981).  It is also necessary to
have  follow-up  training of two to four hours after the  initial  training
program.

     For  U.S.  EPA personnel,  the selection of the appropriate respirator
must be based on the assessment of the hazards and the Decision Logic Table
specified in EPA Order 1440.3.   The inspector's preliminary assessment  of
the potentially hazardous conditions should be discussed with plant person-
nel  before starting any inspection.   In the selection of the respirators,
it may also be beneficial to read the three references listed below, copies
of which will be made available during the training program.

          1.  Respiratory Protection Program Guideline, U.S. Environmental
              Protection Agency, Draft Dated February 1983.

          2.  NIOSH/OSHA Pocket Guide to Chemical Hazards, U.S. Department
              of Health And Human Services of the U.S.  Public Health  Ser-
              vice and the U.S. Department of Labor, Dated September 1978.
              Available from the Superintendent of Documents, U.S.  Govern-
              ment Printing Office, Washington, D.C. 20402

          3.  Respiratory Protection, A Manual and Guideline, Prepared by
              L.R. Birkner, Celanese Corporation and Published by the
              American Industrial Hygiene Association, Dated 1980
                                  122

-------
SLIDE 6-75
     REQUIREMENTS CONCERNING
        USE OF RESPIRATORS
These  are the minimum  requirements
for a respirator program which meets
the specifications outlined in  OSHA
Standard 1910.134.

1.   Written standard operating pro-
cedures  governing the selection and
use  of respirators shall be  estab-
lished.

2.  Respirators shall be selected on
the  basis of hazards to  which  the
worker is exposed.

3.  The user shall be instructed and
trained in the proper use of respir-
ators and their limitations.
4.   Where  practicable,  the respirators should be assigned to
workers for their exclusive use.
                          individual
5.   Respirators shall be regularly cleaned and disinfected.    Those issued
for  the  exclusinve use of one worker should be cleaned after  each  day's
use,  or more often if necessary.  Those used by more than one worker shall
be thoroughly cleaned and disinfected after each use.

6.   Respirators shall be stored in a convenient, clean, and  sanitary loca-
tion.

7.  Respirators used routinely shall be inspected during cleaning.   Worn or
deteriorated  parts shall be replaced.   Respirators for emergency  use such
as  self-contained  devices shall be thoroughly inspected at  least   once  a
month and after each use.

8.  Appropriate surveillance of work area conditions and degree of  employee
exposure or stress shall be maintained.
9.   There  shall  be regular inspection and evaluation  to
continued effectiveness of the program.
                      determine  the
10.   Persons  should not be assigned to tasks requiring use of respirators
unless it has been determined that they are physically able to perform  the
work and use the equipment.   A local physician shall determine what health
and  physical  conditions are pertinent.   The  respirator  user's  medical
status should be reviewed periodically (for instance, annually).

H.   Approved  or  accepted  respirators  shall  be  used  when  they  are
available.   The  respirator  furnished shall provide adequate  respiratory
Protection  against  the  particular hazard for which  it  is  designed   in
accordance with standards estiablished by competent authorities.   (portion
of  this  paragraph has been omitted,  the reader  is referred to  the OSHA
Standard.)
                                     123

-------
SLIDE 6-76
                                       The
            SELECTION CRITERIA
    • Concentration of Contaminants
    • Forms of Contaminants
    • Oxygen Levels
    • Size and Shape of Head
                                             respirators  must  be  selected
                                        based  on  a  number of  factors,   some
                                        of  which are listed on this slide.
                                        One  of  the  most  important  factors is
                                        the   concentration of  the   material.
                                        The   respirator  must   satisfactorily
                                        perform at  these concentrations.   It
                                        is   also important to  know if   the
                                        concentration  is Immediately Danger-
                                        ous   to Life and Health  (IDLH) and/
                                        or if the concentration  is close   to
                                        the  explosive  range.

      Unfortunately,  the  concentration of the contaminant or  contaminants
is rarely known because the exposures are due  to accidential  and/or inter-
mittent   conditions.   Also,  the  inspector  visits  many individual sites
around  the  control system during the  performance evaluation.   Rarely   is
there monitoring data available for all of  these locations.

     It is very important to know  what the oxygen level is at  the  various
locations  to  be visited.   Many air pollution control systems handle   gas
streams with very low oxygen levels of  3 to 6%.    Even  some small leaks  can
lead  to localized oxygen concentrations below 19.5%,   the point   at which
oxygen deficiency becomes a problem.

     The  warning properties of the materials  must also be known.    This is
best  done by the file review before starting  the  inspection.   If some   of
the chemicals are irritants, a full face piece unit may be required,regard-
less of the concentration.   If the chemical(s) can be  absorbed through  the
skin, protective clothing may be necessary  in  addition  to a respirator.

     The form of the material (gas,  vapor,  fume,  dust,  etc.) must be known
to the extent possible.   This is a verdifficult question, however,  since
the  form  of the contaminant can change after  release  to the  ambient   air
surrounding the control device.  In most cases, the low ambient temperature
condenses vaporous material to form very small  particle size aerosols.    In
some cases,  the materials released can react  very rapidly with sunlight  or
with  available oxygen to form more toxic compounds   than were in  the  duct
originally.   It  is also possible for  one  material   released around pollu-
tion  control  equipment  to react with another to form  very  undesirable
materials.  Atmospheric ammonia can participate in some of these  reactions.
For all of these reasons,  the determination of the form of the material  is
difficult.   It ±s hard even to determine what  combination of chemicals   is
present  at a given time.   Due to these problems  it is advisable  to  avoid
areas  of  potential  exposure if at all possible.   This is  why   so  much
attention  was given to the recognition of  potential  exposure sites  during
the early portion of this lecture.

     Another  factor which must be considered  in the selection of  a  respir-
ator  is  the size and shape of the individuals head.    There  are  usually
several models of each type available,  and  the  unit chosen must be comfort-
able and fit tightly.
                                    124

-------
SLIDE 6-77
                                       This  slide  shows a  typical  logic
                                       used to decide what type of  respira-
                                       tor is necessary.    The decision  is
                                       based  on the form and concentration
                                       of the contaminant(s)  and the  level
                                       of oxygen.

                                       Inspectors  on routine duties should
                                       not  enter areas which are known  to
                                       be immediately dangerous to  life and
                                       health.  Alternative means should be
                                       sought  to determine the  compliance
                                       status of a facility with such  con-
                                       ditions.  Inspectors should  also not
                                       enter  areas which are known to have
                                       less than 19.5% oxygen.

     Regulatory  agency  inspectors rarely have the training   necessary  to
wear  air  line respirators,   hose mask  type  respirators,  self-contained
rebreathers,  or  the combination breathing apparatus.   Areas  where  such
equipment is necessary must be avoided.
     The  most  common types of respirators available to   field  inspectors
include (1) dust and mist masks,  (2) dust,  mist and fume masks,  chemical
cartridge respirators with special filters,  and (3) gas  masks with special
filters.   These  will be discussed in more detail in the following slides.
Information on other types of respirators is available in the  publications
listed earlier.

SLIDE 6-78
                                       This  is a close-up photograph of  a
                                       dust  and mist respirator.   This is
                                       the minimum protection necessary for
                                       exposure to particulate matter. Nor-
                                       mally,  it  is sufficient for  mate-
                                       rials having a permissible  exposure
                                       limit  (PEL)  of greater  than  0.05
                                       mg/m3 or 2 mmpcf.    It is limited to
                                       material  concentrations  which  are
                                       less  than 10 times the  PEL.   This
                                       type  of  respirator must never  be
                                       used when the oxygen content is less
                                       than  19.5% or the concentration  of
                                       the  contaminant is approaching  the
                                       level which is immediately dangerous
                                       to life and health (IDLH).

     To be of any benefit,  the mask must be fitted properly.  Beards, side
burns,  and  moustaches can prevent a good fit.   This type  of  respirator
should  be  discarded whenever the resistance to breathing increases,  the
unit is damaged,  and after completing the inspection at  a specific  plant.
They should not be used when gaseous or vapor phase pollutants are  possible
in the breathing area.
                                    125

-------
 SLIDE 6-79
                                       The maximum allowable concentrations
           MAXIMUM                   ^or  Us:"-n8 the dust and  mist  masks
                                       are  relatively low.   To illustrate
          ALLOWABLE                 this,   take the Permissible Exposure
       CONCENTRATION               Limit   specified in  the  NIOSH/OSHA
                                       Pocket  Guide and multiply by a num-
                                       ber  not greater than  10.   Compare
                                       the result with the concentration of
                                       the material in the duct,  stack, or
                                       control device.   In most cases, the
                                       the  gas stream levels are one  hun-
                                       dred to one thousand times the maxi-
                                       mum  allowable levels indicated  for
                                       dust/mist  mask use.   Even a  small
                                       gas  stream leak into the  partially
                                       confined areas around the  equipment
                                       could lead to excessive levels.

     The  dust/mist mask is an acceptable respirator when only  particulate
is  in the air and when it is possible to avoid partially confined areas or
parts  of  the plant downstream of heavy fugitive emissions such  as  those
shown in  this slide.
SLIDE 6-80
                                       This  is a dust,  mist and fume type
                                       mask.   It is appropriate for  short
                                       term exposures to very low mass con-
                                       centrations  of particulate  matter.
                                       and when there is the possibility of
                                       exposure  to  metallic fume  or  any
                                       aerosol or condensed vapors.

                                       Like  any  mechanical  filter,   this
                                       mask  does  not  supply  oxygen  and
                                       should  not  be used if  oxygen  the
                                       level  is  less than  19.5%.    These
                                       masks  are not effective  for  gases
                                       and vapors.
     All  processes which operate at elevated temperature  can  conceivably
generate fumes.   The condensation of vaporous material causes small parti-
cle size material to  form.   Some of the materials commonly encountered  by
field inspectors include arsenic trioxide, mercury and lead oxide.

     If the contaminant(s) are irritants it will be necessary to use a  full
face mask respirator rather than the unit shown.
                                     126

-------
SLIDE 6-81
  CHEMICAL CARTRIDGES CANNOT BE USED
         FOR THESE MATERIALS
        Aniline        Nickel Carbonyl
        Arsine        Ozone
        Carbon Monoxide  Phosgene
        Hydrogen Fluoride Vinyl Chloride
              Hydrogen Sulflde
This  is  a half mask type  chemical
cartridge  respirator.   It  can   be
fitted  with a number  of  different
styles  of  cartridges depending   on
the gases, vapors and/or particulate
matter in the breathing zone.

As  a general rule,  the half  masks
can  be used when concentrations   of
hazardous  pollutants are  10  times
the  Permissible Exposure Limit or a
concentration of 1000 ppm, whichever
is  lower.   The full face mask   can
usually be used when the  concentra-
tion  is  100 times the  Permissible
Exposure  Limit or 1000 ppm,  which-
ever is lower.   Neither mask should
ever be used when the concentrations
are  Immediately  Dangerous to  Life
and Health.    This figure is  often
less  than  the  maximum   allowable
concentration  calculated by  multi-
plying the PEL by 10 or 100.
     This  type of respirator does not supply oxygen,   therefore  it  can not
be  used in the oxygen concentration is less than  19.5%  If   the   materials
are irritants, the full mask type of respirator must be used.
SLIDE 6-82
                                            This  is a  partial  list  of  the
                                       materials which  cannot be  well  hand-
                                       led  by  chemical   cartridge  respi-
                                       rators.

                                       Some  of  these  materials  cannot   be
                                       adsorbed  in the cartridge and  some
                                       have  such poor  warning  properties
                                       that  it  is difficult to   determine
                                       when  the  respirator is  no  longer
                                       performing adequately.

                                       Unfortunately,   the list includes  a
                                       number of very common chemicals.
                                     127

-------
SLIDE 6-83
    Source: National Safety Council
                                        This   is a  photograph of a gas mask.
                                        These  masks are  equipped with a full
                                        face mask and a  canister for removal
                                        of  contaminants.    They  can be  used
                                        at  higher   concentrations than  the
                                        chemical cartridge  units.    The chin
                                        type   canisters  are  usually  accep-
                                        table   for  concentrations  up to 5000
                                        ppm and the  industrial   size canis-
                                        ter can often be used up  to  20,000
                                        ppm.    There are canisters available
                                        which   remove acid  gases,   organic
                                        vapors,   ammonia,   carbon   monoxide,
                                        and several other materials.
     This respirator does not supply oxygen,   therefore,  it  cannot   be  used
when the oxygen concentration is less than  19.5%.   Also,  it  should not  be
used  for entry into atmospheres known to be  Immediately  Dangerous  to  Life
and Health.

     This  type of respirator is moderately uncomfortable.   The amount  of
time that it is worn should be minimized.  This  should not be  a problem for
field inspectors because most areas visited do not have high enough concen-
trations  to  require this type of unit.   The inspector  should not  be  in
areas of high concentration.

     Some  of the problems associated with this  unit include fogging of the
face plate and difficulty in the mounting of glasses.   These  units  should
be cleaned and disinfected after each use and  inspected regularly to ensure
that they will work properly.
SLIDE 6-84
                       Spring
                 	
        %Carbon monoxide catalyst
         	
                       ..
          Organic vapor adsorbent
This  is a cross sectional view of a
canister.   The  average  life of  a
canister at the upper  concentration
limit  is in the range of only 20 to
30 minutes.

After  use,  the canister should  be
destroyed to prevent accidential re-
use.   An  old canister should never
be used.   It is much better not  to
do  the inspection than to go into a
potentially  contaminated area  with
an exhausted canister.
                       Check valve
                                     128

-------
SLIDE 6-85
  Source:  National Safety  Council
This  is a self-contained  breathing
apparatus  (SCBA).   It is  required
when  there  is a  suspected  oxygen
deficiency, when there are high con-
centrations of known pollutants, and
when there are significant levels of
unknown contaminants.

There are three basic types: (1) The
demand  or pressure demand open cir-
cuit  systems,  (2) self  generating
closed  circuit  devices,   and  (3)
liquid or compressed oxygen,  closed
circuit (rebreathing) devices.
     Very  detailed unit-specific training is necessary be fore an  indivi-
dual should use a SCBA.  The training should include instruction in fitting
the face plate, and regular cleaning and inspection of the component parts.

    Only  those  units which operate with a positive pressure in  the  face
Plate  should  be used in contaminant concentrations which are  potentially
Immediately Dangerous  to Life and Health.   All SCBAs, if they are in good
condition  and are used properly,  can provide protection  for  atmospheres
having less than 19.5% oxygen.

    Most  regulatory  agencies  can not afford this  style  of  respirator.
Usually   only  personnel  assigned to especially hazardous duty  (such  as
hazardous dump site investigation, and emergency response) have this equip-
•nent.  Normally,   the  air pollution control inspector is not involved  in
such duties,   therefore,  he or she will not usually have SCBAs  available.
This means that areas where SCBAs might be necessary must be avoided.
SLIDE 6-86
                                       All  respirators  used  by   inspectors
                                       should    be   checked   for   tightness
                                       prior  to entering  the contaminated
                                       area.   In the  case of the  chemical
                                       cartridge and  gas  mask type  units,
                                       there  are several  qualitative tests
                                       which can be  done in the field.   The
                                       tests are listed  in this slide.

                                       The  negative pressure the inlet   of
                                       the cartridge or  canister  is blocked
                                       and the wearer  inhales gently.    The
                                       face plate should  collapse  slightly
                                       and there should  be not obvious   in-
                                       leakage.   The test  itself  can result
                                       in  a respirator not fitting  properly
                                       any longer, therefore,  this  provides
                                       only a  very rough check of  the  fit.
                                    129

-------
SLIDE 6-87

                                       This  is a continuation of the qual-
          ~....._.,..,-.-._,-~».          atitive  means to check the  fit  of
          QUALITATIVE FIT TESTS          cartridge and gas mask type units.
              • Banana Oil
              • IrritantSmoke               The  positive pressure test is  very
                                       similar  to  the  negative  pressure
                                       test.   The exhaust valve is blocked
                                       for  a short period of time.   If  a
                                       slight  positive  pressure  can   be
                                       maintained without any obvious leak-
                                       age then there is a rough indication
                                       that  the respirator seals properly.
                                       This  test also can disturb the  fit
                                       of the respirator.

      The  isoamyl acetate vapor test is conducted by inserting a cartridge
or  canister which removes organic vapor into the  respirator.   The  flask
containing  isoamyl  acetate,  material which has a strong scent of  banana
oil,  is waved in the general vicinity of the individual wearing the respi-
rator.   If the individual can smell the vapor, then the respirator must be
refitted.   The problems with this test are  individual variability in  re-
sponse to the odor and the olfactory fatigue which can result from  several
unsuccessful attempts to seal the respirator.

     Another qualitative test involves the use of an irritant smoke.   This
should  be  done only in an area with good ventilation by a trained person.
This test is less prone than the isoamyl acetate vapor test to the  subjec-
tivity of the individual wearing the respirator.
                                     130

-------
SLIDE 7-1
           PROBLEMS OF
       BIOLOGICAL HAZARDS
This is an area of plant  inspection
safety that is  not often  discussed,
but should be  given consideration by
the  agency inspector.    Hence,  the
next several slides will briefly out-
line the potential biological  hazards
in conducting plant inspections.
      7-2
   TYPES OF BIOLOGICAL HAZARDS
* Viruses
* Bacteria
* Fungi
This slide lists the major categories
of biological hazards.   The first  two,
bacteria and  viruses,  are  hazardous
because of the potential of some kinds
to infect humans  and cause  disease.

The third,  fungi,  such  as molds  and
spores, are hazardous because  of  the
intrinsic toxins  in  some  varieties
and their  potential  to  cause lung
problems upon inhalation.   The routes
of entry  for  biological hazards tend
to be  Inhalation,  ingestion,  and  eye
contact.  Contact  with  the  skin,  ex-
cept (1)  in the  case   of a  cut   or
other opening or  (2) transfer  to  the
mouth does not tend to be as  much of
a problem.
                                      131

-------
SLIDE 7-3
                                         Here  is one  example  of a commonly
                                         encountered potential  biological  ha-
                                         zard.  This inspector  is  attempting
                                         to obtain a  scrubber  liquor  sample.
                                         Since it is possible that  the liquor
                                         might contain bacteria, the inspector
                                         should avoid contamination of his skin
                                         and clothing.   It would be preferable
                                         to sample from a valve, but when sam-
                                         pling the liquor from a valve he would
                                         then have to be careful not to splash
                                         the liquor.
      SOURCES WITH POTENTIAL
        BIOLOGICAL HAZARDS
• Municipal Incinerators
• Pathological Incinerators
* Foodstuff Processors
 SLIDE  7-4                                This  is a partial listing of indus-
                                         tries and source types that  may  have
                                         potential biological hazards.  In the
                                         case  of  municipal  incinerators,  the
                                         inspector should simply avoid contact
                                         with  the  refuse  and refuse  handling
                                         equipment.

                                         Pathological ^incinerators are used to
                                         dispose of refuse from  hospitals,  in-
                                         fectious disease laboratories,  and
                                         other research  facilities.   This  ref-
                                         use can contain potentially  infectious
                                         material.   Once again,  the  inspector
                                         should  avoid  coming  in  contact  with
                                         any of  the material  and in this case,
                                         he might  consider respiratory protec-
                                         tion  if he must  spend  any time  near
                                         the refuse.

     Agricultural operations may  potentially  have biological hazards because
foodstuffs are  an  excellent  medium  for fungal  and  bacterial growth.   One
example of this  is  molds  growing on the grain  in grain elevators.   One mold
in particular,  aspergillus,  that  grows on grain contains  the very harmful
toxin, aflatoxin.

     Some inspectors have expressed concern over  inspecting genetic  engineer-
ing firms.  The  organisms used by these firms  to clone genes and  make  the
product are always  of  a variety which does not survive in anything  but con-
trolled laboratory conditions.   Thus, there is probably no risk  to the inspec-
tor from these organisms.

     Regarding personal protection  against  biological hazards,  the first  re-
commendation is  to  avoid  the hazards  (e.g.  sampling scrubbber liquor without
allowing skin or eye  contact).   As a precaution  against  inhalation of air-
borne fungi and bacteria, a disposable dust mask  can be worn.  Eye protection
should be worn in situations where splashing of contaminated water  is possible;
and, of course,  one should  take care to avoid  rubbing  the  eyes at ANY time*
A practical  recommendation  for  followup to  all inspections is  removal  and
washing of clothes and washing of the body.
                                     132

-------
SLIDE 7-5
     PROBLEMS OF CHEMICALS
             WHICH
    ABSORB THROUGH THE SKIN
Although probably not one of the most
significant air inspection safety prob-
lems, the  inspector should  at least
be aware of the potential for chemical
hazards to the skin.
SLIDE  7-6

   ROUTES OF CHEMICAL EXPOSURE
* Inhalation
* Ingestion
* Skin Absorption
* Skin or Eye Contact
Toxic chemicals can enter the body by
various routes.   The most  important
route of exposure is inhalation which
was discussed  at length previously.

Ingestion is another route  of chemi-
cal exposure.  It is not usually the
cause of  industrial  exposures.   It
can usually be effectively controlled
by never eating  or  smoking  with con
taminated hands  or  in  contaminated
areas.

After inhalation, skin or eye contact
and skin absorption are the next most
common industrial exposure routes.
Skin contact with many chemicals,
even with  no  absorbtion,  can  cause
primary irritation (such as that from
many acids, alkalis, and organic
solvents) and  resulting  skin  damage
or dermatitis.
    In the case of skin absorption, the agent may penetrate and cause sensiti-
j tion to  repeated exposures (like the catechols in poison ivy) or penetrate
:|J sufficient  amounts  to cause systemic poisoning  (such as with significant
 *tn exposure  to  phenols) .   Chemical contamination of the  eye can result in
       degrees  of eye  irritation or in absorption  and systemic poisoning.
                                      133

-------
SLIDE 7-7
    SKIN ABSORBABLE SUBSTANCES
Phenol
Nitrobenzol
Aniline Oil (and derivatives)
Carbon Tetrachloride
Turpentine
Nitroglycerine
Cresol
Hydrocyanic Acid

Benzene

Cyanides
Naphthalene
Xylene
                                         Regarding skin exposure to chemicals,
                                         the agency inspector  has  one advan-
                                         tage over  most  plant  personnel  in
                                         that he  is  less  likely  to  undergo
                                         chronic (repeated or  prolonged)  skin
                                         exposure to  one chemical.   Thus, oc-
                                         cupational dermatitis  is  not  as much
                                         of a problem.  He must, however, still
                                         deal with acute exposures to both the
                                         primary irritants  and the  chemicals
                                         which absorb  through the skin.

                                         General categories of  chemicals that
                                         should be suspected as  primary irri-
                                         tants and avoided  include:  inorganic
                                         and organic acids, inorganic alkalis,
                                         amines, metallic  salts,  and  organic
                                         solvents. A   number   of  these  irri-
                                         tants produce   their  effect  moments
                                         after contact  and  obviously should be
                                         immediately washed  off  using  appro-
                                         priate procedures.

     Others may not  show any effects for  several hours  or days.   Thus, it is
important to avoid  contact in the first place.   The Pocket Guide  to Chemical
Hazards (see Bibliography) indicates  chemicals  which are primary  irritants
with the notation  "Con"  (meaning skin and/or eye  contact)  in  the  "Route" (of
entry) column.   It also provides  the appropriate first aid measures for chem-
ical skin contact and it describes appropriate personal sanitation procedures
(washing and  changing  of  contaminated  clothes)  for  over  380  chemicals.

     This slide lists some of the more  common  chemicals which actually pene-
trate through the skin  into the system  and  cause internal problems including
damage to the central  nervous system and  organs such as  the  liver.   For ex-
ample, phenol is  absorbed through the  skin quite readily and exposure  of a
large part of the body  (as the result  of a  spill, etc.) can result in death.
The Pocket Guide also lists skin absorption hazards using  "Abs"  in the Route
column.  It is recommended that the inspector,  prior to  visiting any facility
using large quantities  of  certain chemicals,  check the  entry  in the handbook
for each chemical to assess its potential effect on the skin including route of
entry, first aid, and personal sanitation  procedures.
                                       134

-------
      FACTORS INFLUENCING
        SKIN ABSORPTION
Sustained, profuse sweating
Fat-dissolving agents
Friction
Amount of oils
Length of contact
Breaks in skin
Hyperemia
Age of skin
SLIDE 7-8                                This last slide lists  a  number  of the
                                         factors which  influence skin absorp-
                                         tion.  Profuse  sweating  can deprive
                                         the skin of oils or increase  friction
                                         in some areas  of  the body,  both  of
                                         which will facilitate  absorption.

                                         Agents which solubilize lipids  (fats
                                         in the skin)  can  penetrate the  skin
                                         themselves or  create  an opportunity
                                         for other  substances  (that  normally
                                         would not have) to penetrate.

                                         The amount of  oil  in the skin has  an
                                         affect on absorption; the  more  oils
                                         the less absorption.

     Length of  contact  with the  substance  is  very significant.   Hence  the
importance of  washing after possible  contact and removing clothes  that  are,
or may be, contaminated.

     Breaks in the skin  obviously allow some chemicals to enter the body  that
otherwise would not  have and allows  others to get  in  faster.  Hyperemia,  or
increased blood flow to  the  skin, also promotes absorption.  And finally, the
younger the skin the greater the absorption of chemicals.
                                     135

-------
136

-------
SLIDE 8-1
    SAFETY CONSIDERATIONS
          IN THE USE OF
    PORTABLE INSTRUMENTS
                                       It   is important to  recognize  when
                                       portable  instruments are  necessary
                                       and  when it is safe to use the  in-
                                       struments.   This  lecture  concerns
                                       some of the basic safety procedures
                                       for  portable  instruments  such  as
                                       static pressure gauges,  pH  meters,
                                       thermocouples, and pitot tubes.

                                       Prior  to using any instruments in a
                                       plant,  the procedures to be follow-
                                       ed   should be discussed  with  plant
                                       representatives
     BATTERY POWERED EQUIPMENT

 • ph Meters
 • Thermocouples
 • RashUghts
SLIDE 8-2

                                       Some of  the portable instruments are
                                       battery  powered.   The most  common
                                       instruments  with internal batteries
                                       are  digital  thermocouples  and  pH
                                       meters.    These instruments  should
                                       not  be  taken  through  areas  with
                                       potentially  explosive dusts or  va-
                                       pors.    It  is possible for them  to
                                       provide  a source of ignition for the
                                       explosive materials.   Before taking
                                       such  instruments into a plant it is
                                       necessary  to get a hot work  permit
                                       from  plant  representatives.   Only
                                       instruments  which are specified  as
                                       intriniscally  safe  for   hazardous
                                       locations can normally be used where
                                       there    are  potentially   explosive
                                       dusts and/or vapors.

      In  the case of the pH meter,   it is almost always possible to  leave
the  meter in a protected area  and bring the liquor sample to  it.   Often,
the  plant  chemical  laboratory  is a convenient location to leave  the  pH
meter.  A dial-type thermometer can be  substituted for the digitial thermo-
couple if there is any question concerning the  safety of the thermocouple.

     The  problems  with battery  powered instruments also apply  to  flash-
lights.  Inspectors should use  only explosion proof flashlights.  The plant
representatives  should  confirm  that  the flashlights  comply  with  plant
restrictions.
                                    137

-------
SLIDE 8-3
                                       Only  the instruments necessary  for
                                       the  inspection  should be  carried.
                                       In trying to carry too much,  it  is
                                       possible  to have an accident  while
                                       walking through areas with obstacles
                                       and while climbing.

                                       Bulky items should not be carried in
                                       pants  pockets.   This restricts the
                                       natural  climbing actions and  makes
                                       an accident more likely.

                                       One  convenient  way  to  carry  the
                                       portable  instruments  is  shown  in
                                       this slide.   The side pouch  allows
                                       free  movement of the legs and frees
                                       the hands for climbing and support.

     As  discussed  during lecture #2,  this slide also shows  one  of  the
limits of side pouches.   Long items such as the dangling dial type thermo-
meter should not be carried.   When it is necessary to get bulky items like
6 foot pitot tubes to elevated platforms,  it is generally necessary to use
a rope.
SLIDE 8-4
           HEROIC PORTS
Only  measurement  ports  with  safe
access  should be used.  NEVER  MAKE
HEROIC  EFFORTS TO USE A PORT  WHICH
HAS BEEN IMPROPERLY LOCATED.  Unfor-
tunately,  a  large number  of  such
measurement  ports exist.   The next
set  of slides shows some  of  these
undesirable ports.

If  there  are no  safe  ports,  the
preferred  locations should be  dis-
cussed  so that plant personnel  can
put  in measurement ports  prior  to
the next inspection.
                                    138

-------
SLIDE 8-5
                                       A  close-up view of a pulse jet bag-
                                       house is shown in this  slide.   The
                                       port  on the inlet ("dirty") side of
                                       the baghouse is shown in the  center
                                       of this slide.  To reach the port it
                                       would  be necessary to reach over  a
                                       42 inch diameter inlet duct carrying
                                       hot  gas.   It should also be  noted
                                       that  inlet ductwork is on the  edge
                                       of the building roof,  therefore, it
                                       is  impossible to stand in the  area
                                       between the ductwork and the  fabric
                                       filter.
     The  inlet port easily could have been placed at one or more locations
along the inlet ductwork.   The value of the static pressure measured would
have  been very similar to that measured at the port shown.   The ports  in
the inlet ductwork would have been both convenient and safe.
SLIDE 8-6
                                       This  is the same baghouse shown  in
                                       the  previous slide.   A slack  tube
                                       manometer is shown just to the right
                                       of the caged access ladder.   If one
                                       of the two ports of this  instrument
                                       had  plugged,  it would be necessary
                                       to disconnect the leads and rod  out
                                       the ports.   Then the portable gauge
                                       could  be  attached and  the  actual
                                       static pressures measured.   In this
                                       case, however, it would be necessary
                                       to  lean  out  through the  cage  to
                                       reach the ports.  These ports should
                                       not be used.
     It  is very common to find the situation depicted in this  slide.   In
some  cases  it would be necessary to climb up the outside of the  cage  to
reach the ports.  THESE PORTS SHOULD NEVER BE USED!  Ladders are for climb-
ing only and are not intended to be used as temporary sampling platforms or
gymnastic equipment.
                                    139

-------
SLIDE «-/
                                       In  the dimly lit  upper  portions   of
                                       this  tray type scrubber  there   are
                                       two  apparent measurement ports   ac-
                                       ross one of the trays.   The only  way
                                       to  reach these ports is to stand on
                                       the top of the hand rails around  the
                                       access platform.    DO NOT STAND   ON
                                       THE  TOP  OR MID RAILS OF ANY GUARD
                                       RAIL.   They  are  not intended   for
                                       this purpose and a very  serious fall
                                       is possible.  Sometimes  it is diffi-
                                       cult  to  resist the  temptation   to
                                       climb  on the guard rail since some
                                       plant  personnel will occassionally
                                       do  this.   Always resist  this   ap-
                                       proach.
SLIDE 8-8
                                       The  measurement ports on this small
                                       pulse  jet collector are located  on
                                       side  (right center of  the  slide).
                                       There  is  a gap of approximately  3
                                       feet  between the collector and  the
                                       end of the roof.   It is 40 feet  to
                                       the ground from this location.   The
                                       plant  personnel  may wish to  reach
                                       the  ports by leaning a ladder  from
                                       the  building roof (left portion  of
                                       slide)  to  the   collector.    This
                                       should  not be done.   If the ladder
                                       were to slip,  a very serious  acci-
                                       dent could occur.  Complicating this
                                       particular  situation  was the  fact
                                       that  the roof was  slightly  sloped
                                       and   was  covered  with  moderately
                                       slippery  solids.   In any  case,  a
                                       portable  ladder should not be  used
                                       to cross a chasm between the walking
                                       surface and the collector.
                                     140

-------
 SLIDE  8-9
                                       In many cases,  the only ports which
                                       are available are the 4 inch diamet-
                                       er stack sampling ports.  In some of
                                       the smaller plants there may not  be
                                       a   sampling  platform  around   the
                                       ports.   As shown in this slide,  it
                                       is  possible  to reach the ports  by
                                       riding in the bucket of a front  end
                                       loader.   THIS  SHOULD NOT BE  DONE.
                                       The  bucket is not intended to serve
                                       as a temporary sampling platform and
                                       the  bottom is far from  level  when
                                       the bucket is in the position shown.
                                       A  fall  against  the  side  of  the
                                       bucket  could  result in  a  serious
                                       head injury.

      The  buckets  generally contain at least a small quantity  of  solids
which can be quite slippery.   Furthermore,  the operator of the front  end
loader  could  make a mistake and dump the inspector.   A front end  loader
should not be used as a sampling platform under any circumstances.
SLIDE 8-10

                                       This  is the inlet duct to  a  small
                                       baghouse  which  operates at a  high
                                       gas temperature.   The skin  temper-
                                       atures  of  both the collector  side
                                       wall and the flange to the right  of
                                       the  measurement  port are  320  °F.
                                       While attempting to open the port,  a
                                       burn is likely.  The port could have
                                       easily  been placed several feet up-
                                       stream of the flange or on the  side
                                       wall  of the collector and  provided
                                       the  same data.   This was the  only
                                       location where there was an unavoid-
                                       able burn hazard.

      Whenever working with hot ducts (most are hot), the inspector must be
very  conscious of the access to the port and the general clearances around
the entire platform. It is easy to inadvertently leaning against a hot duct
wall  while trying to stand up or while trying to move around  a  cluttered
platform area.
                                    141

-------
SLIDE 8-11
                 m
                                       The inspector  shown in  this  slide  is
                                       about   to suffer  a  burn on   the  hot
                                       wall  of  this  scrubber.  This is  on
                                       the inlet portion of the unit,   at a
                                       location   before  the gas stream  has
                                       had an opportunity  to cool.   Gloves
                                       should be  worn  and the dial   type
                                       thermometer  should be  held  in   the
                                       manner shown.
SLIDE 8-12
itei &

        !   I
                                       When  selecting  measurement  ports,
                                       choose the smallest one which allows
                                       use of the various probes.   The one
                                       half inch port shown in the slide is
                                       often an ideal size.  The very large
                                       4  inch  diameter  ports  can  allow
                                       substantial  flow of pollutant laden
                                       gas into the breathing zone.
                                    142

-------
SLIDE 8-13
                                       Whenever instruments are used  after
                                       electrostatic  precipitators  it  is
                                       important to use a grounding/bonding
                                       cable.    It  should be attached prior
                                       to  insertion of the probe or  pitot
                                       tube into the duct.   The gas stream
                                       passing the port contains has parti-
                                       cles with a  high static charge.  The
                                       static  charge can accumulate to very
                                       high static  voltages on the probe or
                                       pitot tube.

                                       The shock suffered by the  inspector
                                       may  not have a high enough  current
                                       to  be  fatal,  but,  it can surprise
                                       the individual and result in a  fall
                                       off  the platform.  Also,  the shock
                                       can be  quite painful.

     It  is  also necessary to ground all probes when  making  measurements
within fiberglass ducts.   The duct walls can  accumulate a very high static
charge.   As  the probe is approaching the measurement port,  a spark  will
jump from the duct to the probe.   This can be as painful and surprising as
the shocks suffered downstream of precipitators.
SLIDE 8-14
                                       Static   grounding/bonding    cables
                                       should be used whenever there is the
                                       possibility that static will accumu-
                                       late on the probe while it is in the
                                       gas  stream.   This can happen when-
                                       ever the particulate mass concentra-
                                       tion  is  relatively  high  and  the
                                       relative  humidity  is  low.   Under
                                       such  conditions  the static  charge
                                       probably can reach levels sufficient
                                       to  cause a spark over to  the  duct
                                       wall  (near  the measurement  port).
                                       If  the dust is explosive and  there
                                       is sufficient oxygen, then an explo-
                                       sion will result.
     It  should  be noted that this problem has not been reported  and  the
potential  for an explosion is only speculation at this time.    However,   a
large  majority of the gas streams at elevated temperature have too  low  a
relative  humidity to allow dissipation of the static charge.    Also,   most
gas streams at the inlets of the air pollution control systems have a   high
enough  mass concentration to be in the explosive range.   Some ducts   also
contain deposits of solids which could be explosive.    In some cases,  there
is  enough oxygen for an explosion.   For all these reasons,   there is  the
potential  for  a major explosion due to the static charge.   It should  be
continuously  drained  off by using the grounding/bonding cables  shown  in
this slide.
                                     143

-------
SLIDE 8-15
                                       When using an oxygen and carbon  di-
                                       oxide  analyzer of the type shown in
                                       this  slide,  care is  necessary  to
                                       prevent  contact with the  corrosive
                                       absorbing solutions.  There is a top
                                       valve  used  for admitting  the  gas
                                       sample.   When absorbing the compon-
                                       ents  of the gas sample,  the entire
                                       instrument is inverted several times
                                       to  mix the gas with  the  absorbing
                                       solution.   This  top valve must not
                                       be  depressed  while  inverting  the
                                       instrument  because  the   corrosive
                                       liquid will spill out.

     If for any reason there is contact with the liquid, wash it  off imme-
diately.   The  oxygen  solution contains hydrochloric acid and  the  carbon
dioxide solution contains potassium hydroxide.
SLIDE 8-16
                                       When  obtaining a liquor sample  for
                                       pH  measurement  or other  analysis,
                                       contact  with the liquor  should   be
                                       avoided.    The slide illustrates  the
                                       wrong way of acquiring a sample.

                                       In  some  cases,  the liquor contains
                                       bacteria   and  viruses.     Chemicals
                                       which can be rapidly absorbed  by  the
                                       skin may  also be present.
                                     144

-------
SLIDE 8-17
                                       This  is   a  port  for  a  reverse  air
                                       baghouse   operating at approximately
                                       400 °F on a  continuous  basis.    Hie
                                       plug  for this port will remain  hot
                                       as long as several hours after  being
                                       removed.   Some people forget  about
                                       this  problem  and pick up the   plug
                                       with bare hands.

                                       When  withdrawing a probe  or  pitot
                                       tube  from a hot  gas  stream,  gloves
                                       should be used to hold  the  probe.
                                       These  probes can be  at temperatures
                                       ranging from 200  to 1200 °F.
SLIDE 8-18
                                       While  making  fan rotational  speed
                                       measurements,  care must be taken to
                                       prevent entrapment between the belts
                                       and the sheaves.   A partially expos-
                                       ed belt as shown  in this slide  must
                                       be avoided.  Only belt guards with a
                                       small  access port and good  protec-
                                       tion  around  the entire sheave  and
                                       belts should be used.
                                     145

-------
SLIDE 8-19
                                       When using a long probe such as a  6
                                       to 8 foot pitot tube, all high volt-
                                       age  lines  and tracks must be  com-
                                       pletely avoided.  It is not uncommon
                                       to have a high voltage line 10 to 15
                                       feet above a collector or to have  a
                                       high voltage track within 10 feet of
                                       a collector.   As the pitot tube  is
                                       being withdrawn, it may approach one
                                       of  this  and allow a spark to  jump
                                       the gap.  This can result in a fatal
                                       shock.   Measurement  ports  in  the
                                       general  vicinity  of  high  voltage
                                       lines must be avoided.
SLIDE 8-20
                                       Many control  devices operate  at  very
                                       high negative static pressures.    If
                                       the  measurement port is  as large  as
                                       that shown on this  slide, it  is  pos-
                                       sible to  lose the probe into  the gas
                                       stream.   At the  very best this would
                                       be  embarrassing.   Under the worst
                                       circumstances, this could damage the
                                       fan  downstream   and result  in  the
                                       disintegration of the fan.  Ports  of
                                       this  size should be avoided  if  at
                                       all possible.
                                    146

-------
SLIDE 8-21
                   SANDING DISK

                     COPPER TUBE
                     RUBBER STOPPER
        -DUCT WALL
                                       This slide illustrates one means   to
                                       prevent  loss of the probe into   the
                                       high negative static pressure ducts.
                                       This  consists  of a rubber  stopper
                                       (drilled to be slightly small)  fol-
                                       lowed  by  a. commercially  available
                                       sanding  disk having a quarter  inch
                                       hole.   The sanding disk must be   at
                                       least  one  inch larger in  diameter
                                       than the port being used.   The rub-
                                       ber  stopper holds onto the  quarter
                                       inche  O.D.  probe and  the  sanding
                                       disk  holds onto the rubber stopper.
                                       This assembly has been used up to  a
                                       static  pressure  of -120 inches   of
                                       water  without  any  problems.    The
                                       main limit of this approach is  that
                                       The sanding disk can not be used  for
                                       very hot ducts.
             SUMMARY
SLIDE 8-22

                                       Since   there  are  some  additional
                                       risks  inherent  in the use  of  any
                                       portable  instrument,   they  should
                                       only  be used when there is a  defi-
                                       nite need for the data.   Use of the
                                       instruments should be discussed with
                                       plant   representatives  before  the
                                       inspection.

                                       Only  measurement  ports  with  safe
                                       access  and adequate  clearance  for
                                       high  voltage lines should be  used.
                                       The  potential for burns and/or  ex-
                                       posure to toxic gases should be kept
                                       to a minimum.

     The  battery powered and line voltage instruments should not be  taken
into areas where there are potentially explosive dusts and/or vapors.   All
Probes  used in ducts where there is the potential for static  accumulation
should  be  bonded to a grounded duct.   Suction of the probe into the  gas
stream absolutely must be prevented.
                                    147

-------
148

-------
SLIDE  9-1
  AGENCY SAFETY PROGRAM
Any agency  (or  other   organization)
whose personnel  are  involved in  air
pollution control   equipment   inspec-
tion and/or  maintenance  should  have
an organized  safety program  designed
to minimize the risk involved in these
operations.  The  U.S.   Environmental
Protection Agency  (EPA)  has  taken  a
lead in this  area  in response  to the
Occupational Safety and  Health  Act of
1970 and  other  government   mandates
and has itself set up  a very  struc-
tured program.

This lecture  outlines   the   elements
and goals  which  are  basic  to   any
safety program of  this  type.  It  is
to every inspector's advantage  to find
out about his  employer's program (if
any) and to assist  in instituting one
if there is none.
     9-2
!• Written Safety Procedures (Guideline Manual)
*• Regular Safety Training
* Basic Protective Equipment
'• Medical Monitoring
This slide lists  four basic elements
of a safety  program.   All field per-
sonnel should have access to a written
safety procedures  guideline  manual,
regular training in appropriate safe-
ty procedures, basic personal protec-
tion equipment for their duties, and
regular medical  monitoring  examina-
tions.
                                      149

-------
SLIDE 9-3
     SAFETY GUIDELINES MANUAL
  Recognition of Hazards
  Symptoms of Exposure
  Safety Procedures for Hazards
  Emergency Procedures
  Use of Personal Protection Equipment
  Reporting of Illnesses or Accidents
A written   safety  procedures manual
should be  prepared by every regulato-
ry agency   and   private  organization
involved in the inspection  (or main-
tenance) of air   pollution   control
equipment.   This  manual  should  out-
line the  agency's  or  organization's
policy concerning   safety  and  at  a
minimum address recognition   of  per-
tinent hazards, recognition  of  symp-
toms of  exposure,  safety  procedures
to be  followed for each type of ha-
zard, emergency procedures,   use  of
personal protection   equipment,  and
the reporting   of  illnesses  or  acci-
dents.
     It is recommended that this manual be dated  and  revised whenever  neces-
sary.  All personnel  covered  by these  guidelines should  be responsible  for
reading them carefully and  for effecting needed modifications.
SLIDE 9-4
          SAFETY TRAINING
  Safety Procedures
  Use of Personal Protection Equipment
  CPR and First Aid
All field  personnel should  also par-
ticipate in  a  mandatory  program  of
safety training.   This  training pro-
gram would include instruction in re-
cognition of  potential  hazards,  ap-
propriate safety  procedures, and pro-
per use of personal protection equip-
ment.  A judicious program would also
include instruction in  Cardio Pulmo-
nary Resuscitation  (CPR)   and  basic
First Aid.

This training   should  be   regularly
scheduled; at  least  once  a year  I8
suggested.  New   employees   assigned
field duties  should   receive   this
training PRIOR  to   beginning   field
work.  Training   programs   should  t>e
carefully tailored  to  the  duties  of
the individuals  instructed;  for  ex-
ample, an  air inspector assigned the
additional responsibility of respond-
ing to   hazardous   chemical   spiH8
should  receive    considerably   more
safety training  than   one   assigned
only to investigate odor  complaints*
                                       150

-------
SLIDE  9-5
     BASIC PROTECTIVE EQUIPMENT

  Hardhat
  Safety Shoes (steel-toed)
  Safety Glasses and Goggles
  Ear Protection
  Dust, Mist, and Fume Masks
  Cartridge-type Respirators
                                          Agencies  and   organizations  should
                                          also  provide  their  field  employees
                                          with personal   protection  equipment
                                          suited to  their  duties.   This  slide
                                          lists the  basic protective  equipment
                                          recommended for   Inspectors   of  air
                                          pollution control equipment.
SLIDE 9-6
MEDICAL MONITORING PROGRAM

  BASEUNE EXAMINATION
  1. Medical and Occupational History
  2. Physical Examination
  3. Chest X-ray
  4. Selected Blood and Urine Tests
  5. Hearing
  6. Lung Function
  7. Other Special Tests
  ANNUAL MONITORING EXAMINATION
                                          This slide outlines the components of
                                          a suggested  medical  monitoring  pro-
                                          gram.   A medical  monitoring   program
                                          should be designed to assess  the
                                          health status of individuals  prior to
                                          work,  monitor  for  evidence  of post-
                                          work adverse  effects,  and   evaluate
                                          and  treat  work-related injuries   and
                                          illnesses.

                                          Individuals should undergo the base-
                                          line examination prior to doing   any
                                          field  work to  evaluate their suita-
                                          bility for hazardous  assignments   and
                                          capability for proper use of  the  nec-
                                          essary personal protective equipment
                                          and  to establish  baseline or refer-
                                          ence data for  comparison  with find-
                                          ings of future examinations.

      The baseline examination usually consists of a detailed medical and  oc-
cupational history,  a thorough physical  examination,  and a  number of  specific
tests including a  chest x-ray, blood and  urine tests, an electrocardiogram, a
hearing test,  lung function tests, and any other tests indicated by knowledge
of the work  to be  performed.

     The annual monitoring  examination  then provides  a way to detect work-
related adverse health effects and a reassessment of an individual's continued
fitness for assigned  duties.   It can also provide occupational health guidance
and data  for  occupational health studies.   The  annual examination  usually
includes a  history  update;  selected  blood,  urine,   and  pulmonary  function
tests; and a screening physical  exam.
                                       151

-------
152

-------
 APPENDIX A




BIBLIOGRAPHY
153

-------
154

-------
Accident Prevention Manual for Industrial Operations, National Safety
Council, 6th Edition, 1971.

A. M. Best Company.  Best's Safety Directory.  Volumes I and II.  Oldwick,
NJ.  1984.  (Published annually)

American Industrial Hygiene Association.  Direct Reading Colorimetric
Indicator Tubes Manual, First Edition.  Akron, Ohio.  1976.

American Industrial Hygiene Association.  Manual of Recommended Practice
for Combustible Gas Indicators and Portable, Direct Reading Hydrocarbon
Detectors, First Edition.  Akron, Ohio.  1980.

Birkner, L. R.  Respiratory Protection:  A Manual and Guideline, First
Edition.  B. J. Held and B. E. Held (ed.).  American Industrial Hygiene
Association, Akron, Ohio.  1980.

Brief, R. S.  Basic Industrial Hygiene:  A Training Manual.  Prepared for
the Exxon Corporation.  American Industrial Hygiene Association, Akron,
Ohio.  1975.

Burgess, W. A.  Recognition of Health Hazards in Industry.  John Wiley
and Sons, New York.  1981.

Bonney, T. B., et al.  Industrial Noise Manual.  American Industrial
Hygiene Association, Akron, Ohio.  1975.

Drager Corporation.  Drager Gas Detector Tube Handbook, Fifth Edition.
Pittsburgh, Pa.  February 1983.

General Industry Standards Part 1910.  OSHA Publication 2206.  U.S.
Department of Labor, Occupational Safety and Health Administration.
U.S. Government Printing Office, Washington, D.C. 20402.   March 8, 1983.

Hirschfelder, D.  Contact Lenses in the Workplace.  Sightsaving, Vol 52,
(1): 14-18.  1983.

The Industrial Environment - Its Evaluation and Control,  U.S. Department
of Health, Education and Welfare, 1973.

Macklnson, F. W., R. S. Stricoff, and L. J. Partridge, Jr. (editors)
NIOSH/OSHA:  Pocket Guide to Chemical Hazards.  U.S. Dept. of Labor,
Occupational Safety and Health Administration; U.S. Department of Health
and Human Services:  Public Health Services, Centers for  Disease Control,
National Institute for Occupational Safety and Health.  U.S. Government
Printing Office, Washington, DC. 20402.  September 1978.

Occupational Diseases, A Guide to Their Recognition, Revised Edition.
U.S. Department of Health, Education and Welfare.  June 1977.

Patty's Industrial Hygiene and Toxicology,  Third Revised  Edition, Volume 1.
G. Clayton and F. Clayton, Editors.  Wiley-Interscience Publication Page 340.
                                155

-------
A Primer on Confined Area Entry.  Rexnord, Safety Products.  Malvern, PA.


Safety Manual for Hazardous Waste Site Investigation, U.S. Environmental
Protection Agency.  Available from the Office of Occupational Health and
Safety, Waterside Mall, 401 M Street S.W., Washington, D.C.  Draft Manual
dated September 1979.

Sax, N. I.  Dangerous Properties of Industrial Materials, Van Nostrand
Reinhold Company, New York, N.Y.

Schwope, A. D., P. 0. Costas, J. 0. Jackson and D. J. Weitzman.  Guidelines
for the Selection of Chemical Protective Clothing, A. D. Little, Inc. for
U.S. EPA.  American Conference of Governmental Hygiensts, Inc.  Cincinnati,
Ohio.  1983.

Stack Sampling Safety Manual, Prepared by Norman V. Steere & Associates
for the U.S. Environmental Protection Agency.  September 1978.

United Technologies/Bacharach Instruments.  Operation and Maintenance:
Model "L" Sniffer.  Pittsburgh, Pa.  1981.

U.S. Environmental Protection Agency Field Health and Safety Program.
Prepared by Norman V. Steere and Associates, Inc., November 1982 for U.S.
EPA.
                                 156

-------
   APPENDIX B




REVIEW QUESTIONS
  157

-------
158

-------
1.  Cartridge type respirators are usually rated at 	.

      a.  concentrations twice on TLV
      b.  concentrations five times the TLV
      c.  concentrations ten times the TLV
      d.  concentrations fifty times the TLV

2.  The use of hearing protection in high noise areas hinders normal  com-
    munication.

            a.  true
            b.  false

3.  Common "partially" confined areas include	.
            a*  walkways between large control systems
            b.  weather enclosures around hoppers
            c.  weather enclosures around precipitator roofs
            d.  pump houses
            e.  fan houses
            f.  mountings for continuous emission monitors
            g.  all of the above

A.  "Partially" confined areas are particularlly dangerous when
            a.  the ducts or control equipment operate at positive pressure
            b.  the gas streams contain asphyxiants and toxic agents
            c.  the gas streams contain dusts and fumes
            d.  all of the above

5.  Before inserting a probe Into a gas stream it is important to check
            a.  that the grounding cable Is in good physical condition
            b.  that the ground clamp does not interfere with the probe
            c.  that the clamp has penetrated any paint or corrosion layer
                on the ground
            d,  all of the above
6.  Ionizing radiation may be a problem around
            a.  electrostatic precipitator rappers
            b.  continuous emission monitors
            c.  damaged hopper level monitors
            d.  electrostatic precipitator electrical cabinets
                            159

-------
 7.  Falls may be caused by
       a.  slippery surface around wet scrubbers
       b«  climbing ice covered ladders
       c.  crossing roofs with heavy accumulations of snow or solids
       d.  protruding equipment in dimly lit areas
       e.  a and c
       f.  a and d
       g.  all of the above
 8.  Prior to using a respirator, an inspector should
       a.  be trained in the selection and use of respirators
       b.  be trained in the maintenance of respirators
       c.  have a physical examination
       d.  all of the above

 9.  When selecting what personal safety equipment is necessary during an
     inspection, an inspector should be guided by	•

       a.  what the plant representative and other plant personnel are
           using
       b.  plant policies
       c.  agency policies
       d.  common sense

10.  Exposure to particulate and gaseous contaminants often may result
       a.  downwash of effluent from short stacks
       b.  fugitive leaks from ducts and hatches into partially
           confined areas
       c*  fugitive leaks through open static pressure taps
       d.  fugitive leaks around process equipment
       e.  all of the above
11.   Safety shoes should be worn
       a.   only when required by plant policies
       b.   only when required by agency policies
       c.   for all plant inspections
       d.   when specifically required for plant entry

12.   An inspector should not work alone during an inspection,  unless
       a.   plant  personnel are too busy to accompany the inspector
       b.   the inspector is very familiar with the plant
       c.   no entry into partially confined or confined areas is
           anticipated
       d.   the Inspector has all the  necessary personal protection
           equipment
       e.   none of  the above
                              160

-------
13.  Burns may be caused by
       a.  contact with hot gas ducts
       b.  contact with measurement probes, such as pitot tubes
       c.  radiation from process equipment
       d.  high pressure steam leaks
14.  High noise levels are frequently found near
       a.  fans
       b.  screw conveyors
       c.  electrostatic precipitator rappers
       d.  process equipment such as compressors and
           grinding mills
       e.  rotary discharge valves
       f.  steam vents

15.  The suspension of the hard hat needs to be checked at least
             a.  once a day
             b.  once a week
             c.  once a month
             d.  once a year
             e.  never

16.  Most gaseous contaminants have good "warning properties" therefore the
     inspector is usually aware that they are present	.

             a.  true
             b.  false
17.  The routes of entry of toxic compounds include
       a.  the eyes
       b.  the respiratory system
       c.  the skin
       d.  ingestlon
       e.  all of the above

18.  Hazards of opening access hatches include:

       a.  asphyxiation due to free flowing solids found in hoppers
       b.  positive pressure systems creating force on the interior
           of hatch
       c.  control device fires
       d.  burns from hot solids
       e.  hand injuries from "breaking the seal" of hatch
           in negative pressure system

19.  Contact lenses should not be worn during inspections 	
       a.   true
       b.   false
                                161

-------
 20.   Respirator or gas  mask cartridges and canister air purifying capabili*
      ties  are  identified  by both worded labels and a color code.	•

        a.   true
        b.   false

 21.   The use of a  respirator exposes  a worker to additional stress

        a.   true
        b.   false

 22.   The following symptoms may  indicate exposure to air contaminants
       a.  headache
       b.  drowsiness
       c.  shortness of breath
       d.  neausea
       e.  loss of coordination
       f.  eye irritation
       g.  all of the above
       h.  none of the above

23.  Static electricity is especially likely following	.

       a.  a wet scrubber
       b.  a fabric filter collecting dry dust
       c.  electrostatic precipitation
       d.  mechanical collection
       e.  all of the above

24.  Hearing protection is necessary whenever normal conversation cannot
     be heard at a distance of 	 feet.

       a.   1
       b.   2
       c.   5
       d.  10

25.  Most types of hearing protection reduce noise intensity inn the 1000
     to 4000 Hz range by	.

       a.   5 to 10 dB
       b.  10 to 25 dB
       c.  25 to 50 dB
       d.  50 to 75 dB
26.  Fan disintegration can be caused by
       a.  operating at excessive tip speeds
       b.  build-up of material ou the fan wheel
       c.  operating at high gas temperatures
       d.  erosion of the fan wheel
                              162

-------
27.  At high  concentrations hydrogen sulfide has 	 odor.

       a.  a  rotten eggs
       b.  a  sewer
       c.  a  fragrant
       d.  no

28.  Ozone may be generated in	.
       a.  fabric filter
       b.  an electrostatic precipitator
       c.  a wet scrubber
       d.  none of the above

29.  Entry into the confined areas, of a fabric filter or electrostatic  pre-
     cipitator by an agency inspector should be done when 	
       a.  the equipment has been properly locked out
       b.  all components have been properly grounded
       c.  the sytem has been purged out and cooled
       d.  the interior environment ha been tested for oxygen and
           gaseous contaminants
       e.  a properly trained individual is stationed outside to provide
           assistance if necessary
       f.  none of the above

30.  A self-contained rebreather is necessary whenever work is required
     around areas which 	     	
       a.  have less than 19.5% oxygen
       b.  have gaseous concentrations that exceed the safe limit of
           the cartridge and canister type respirators
       c.  have less than 16% oxygen
       d.  have less than 12% oxygen
       e.  have high carbon monixide levels
31.  Access hatches should be opened
       a.  when the system is down and locked out
       b.  when the static pressure differential across the hatch
           is approximately zero
       c.  by plant personnel only

32.  The baseline inspection technique involves entry into the control
     systems for internal inspection.

       a.  true
       b.  false
                              163

-------
33.  If an Inspector experiences the nonspecific symptoms of exposure  to
     gases and vapors, he or she should 	
       a.  continue with the inspection until more definite symptoms
           develop
       b.  discuss the potential exposure with plant personnel
       c.  leave the area immediately and reevaluate the conditions
       d.  all of the above

34.  When climbing ladders, inspectors should keep their hands on the
       a.  side rails
       b.  foot rails
       c.  either

35.  Which of the following symptoms may indicate exposure to air contaminants

       a.  drowsiness
       b.  shortness of breath
       c.  loss of coordination
       d.  eye irritation
       e.  light headedness
       f.  all of the above

36.  During the inspection, the operator of a fabric filter compartment
     serving a cupola states that the previous bag failure problem has
     been corrected by using a new bag hanger design and by modifying the
     tube sheet thimble.  He suggests that you follow him into the fabric
     filter compartment to confirm that this has been done properly.
     What should the inspector do?

       a.  check all six compartments to ensure that the same modifications
           were made in each
       b.  just check one or two compartments
       c.  limit the inspection to what can be seen from the access hatch
           without going inside the compartments
       d.  review the drawings and do not waste time on the equipment
           inspection

37.  An internal inspection of an electrostatic precipitator should be con-
     ducted by an agency inspector when 	.

       a.  there are indications on misaligned plates and wires based on the
           secondary voltges and currents
       b.  there are indications of poor gas distribution and the source is
           making major modifications to the precipitator inlet
       c.  there are symptoms of rapping reentrainment
       d.  the operator has reported severe corrosion problems
       e.  when hell freezes over
                               164

-------
38.  A victim of heatstroke, the most severe heat-induced illness, will
     have which of the following symptoms?

       a.  hot, dry skin
       b.  clammy skin
       c.  confusion
       d.  convulsions
       e.  all of the above
       f.  a, c and d

39.  When should light clothing cover as much of the body as possible to
     prevent heat stress?

       a.  when the temperature is greater than 100°F
       b.  when the temperature is less than 100°F

40.  The single most effective way to prevent heat stress is:

       a.  wear appropriate clothing
       b.  avoid sources of heat
       c.  increase fluid intake
       d.  stay in good physical condition

41.  If the plant personnel seem to be feeling fit, the inspector should
     not worry about heat stress difficulties.

       a*  True
       b.  False

42.  Environmental conditions which increase the likelihood that heat
     stress will occur are:

       a.  steam clouds from control and process equipment
       b.  radiant heat from process equipment
       c.  excessive noise
       d.  all of the above
       e.  a and b

43.  Passive dosimeters have certain characteristics which limit their
     effectiveness.  Some of these are:

       a.  They accumulate very low concentrations of gas over time and may
           show a high concentration of gas when there is no danger.
       b.  They lose their effectiveness when exposed to the ambient  air
           for more than 3-5 days because the water in the indicator paper
           evaporates.
       c.  The incidence of interference gases is higher the longer the
           badge is worn.

44.  Passive dosimeters can be reused because they "regenerate" after
     being removed from the contaminated environment.

       a.  True
       b.  False


                                165

-------
45.  Inspectors should cancel inspections if the wind chill factor is:

       a.  less than -40°F
       b.  less than -30°F
       c.  less than -20°F

46.  Hypothermia and frostbite injuries can be prevented by:

       a.  layering clothing
       b.  staying dry
       c.  taking frequent breaks in warm areas
       d.  consuming warm food and/or beverages

47.  The proper way to acclimate to cold stress is to observe the following
     routine:  Begin with an exposure period of 2 hours, Increase exposure
     10 minutes per day for 5 consecutive days.

       a.  True
       b.  False

48.  Frostbite should be treated by briskly rubbing the affected area with
     snow.

       a.  True
       b.  False

49.  Hypothermia victims may exhibit the following symptoms:

       a.  apathy and dlsorientation
       b.  uncontrollable shivering
       c.  decreased respiration
       d.  increased respiration
       e.  all of the above
       f.  a, b, and c
       g.  a, b, and d.
                                166

-------
 Review Question Answers

 1.  c                                22.  g
 2.  b                                23.  fa,c
 3.  g                                24.  b
 4.  d                                25.  c
 5.  c                                26.  a,b,d
 6.  c                                27.  a
 7.  g                                28.  b
 8.  d                                29.  f
 9.  a,b,c,d                          30.  a,b,c,d,e
10.  e                                31.  a,b,c
11.  c                                32.  b
12.  e                                33.  c
13.  a,b,c,d                          34.  b
14.  a,b,c,d,f                        35.  f
15.  c                                36.  c
16.  b                                37.  e
17.  e                                38.  f
18.  a,b,c,d,e                        39.  a
19.  a                                40.  b
20.  a                                41.  b
21.  a                                42.  d
                                      43.  a,b
                                      44.  b
                                      45.  c
                                      46.  a,b,c,d
                                      47.  b
                                      48.  b
                                      49.  e
                                 167

-------
168

-------
           APPENDIX C

     EXAMPLE OF ONE PLANT'S
SUBSTANCE EXPOSURE SYMPTOM CHART
             169

-------
170

-------
SUBSTANCE
QVEREXPQSURE SYMPTOMS
ACETIC ACID
ACETONE
AMMONIA
ASBESTOS
BARIUM (SOLUBLE COMPOUNDS)
BENZENE
BROMINE
2-BUTANONE (MEK>
CALCIUM OXIDE
CARBON BLACK
CARBON DIOXIDE
CARBON DISULFIDE
CARBON MONOXIDE
CARBON TETRACHLORIDE
CHLORINE
CHLOROBENZENE 
-------
              (CONT'D)
                              -2-
SUBSTANCE
QVEREXPQSURF SYMPTOMS
CHLOROFORM
(TRICHLOROMETHANE)
CHROMIC ACID AND CHROMATES
CHROMIUM, SOL, CHROMIC, CHROMOUS
SALTS AS CR
COAL DUST (RESPIRABLE
FRACTION LESS THAN 52 S^)
COAL TAR PITCH VOLATILES
(BENZENE SOLUBLE FRACTION)
COPPER FUME
COPPER DUSTS AND MISTS
CYANIDE
DICHLORODIFLUOROMETHANE
(FREON-12)

DIPHENYL
ETHYL ALCOHOL
ETHYL ETHER
FLUOROTRICHLOROMETHAHE
(FREON-11)

GRAPHITE (NATURAL)
HEPTANE
HEXACHLOROETHANE
SUSPECT CARCINOGEN/CUMULATIVE
LIVER AND KIDNEY DAMAGE/NARCOSIS

SUSPECT CARCINOGEN/CUMULATIVE
LUNG DAMAGE/NASAL PERFORATION,
ULCERATION

CUMULATIVE LUNG DAMAGE/DERMATITIS
PNEUMOCONIOSIS


SUSPECT CARCINOGEN/CUMULATIVE
LUNG CHANGES

MODERATE IRRITATION EYE, NOSE,
THROAT, LUNG

MILD IRRITATION EYE, NOSE,
THROAT, SKIN

MARKED IRRITATION SKIM, EYE, NCSE
AND THROAT

DIZZINESS,' TREMORS, UNCONSCIOUS;
CARDIAC ARRHYTHMIAS, CARDIAC ARREST

MODERATE IRRITATION EYE, NOSE,
THROAT, BRONCHI, LUNGS

MILD IRRITATION EYE, NOSE,
THROAT/NARCOSIS

NARCOSIS/MILD IRRITATION EYE,
NOSE, THROAT

ACUTE CENTRAL NERVOUS SYSTEM
EFFECTS

CUMULATIVE LUNG DAMAGE
(PNEUKOCONIOSIS)

MODERATE IRRITATION EYE, NOSE,
LUNGS/CENTRAL NERVOUS SYSTEM
EFFECTS/NARCOSIS

CUMULATIVE ORGAN DAMAGE/CENTRAL
NERVOUS SYSTEM EFFECTS
                             172

-------
                              -3-
              (CONT'D)
SUBSTANCE
QYEREXP OSURE_SYMPIQMS
HYDROGEN CHLORIDE


HYDROGEN SULFIDE





IODINE


IRON OXIDE FUME

ISOPROPYL ALCOHOL


LEAD FUMES AND DUST
L,P,G, (LIQUEFIED PETROLEUM GAS)

MERCURY (INORGANIC)


METHYL ALCOHOL (METHANOL)


METHYL CHLOROFORM

METHYLENE CHLORIDE



METHYL MERCAPTAN

MINERAL SEAL OIL (MENTOR 28)


MOLYBDENUM, INSOLUBLE


                              173
MARKED IRRITATION EYE, NOSE,
THROAT/ LUNG EDEMA

ACUTE SYSTEMIC TOXI CITY/MODERATE
IRRITATION EYE, (CONJUNCTIVITIS;
LUNGS/CENTRAL NERVOUS SYSTEM
EFFECTS

MARKED IRRITATION EYES, NOSE,
THROAT/LUNG EDEMA

LUNG CHANGES (SIDEROSIS)

MILD IRRITATION EYE, NOSE,
THROAT/NARCOSIS

INSOMNIA/ LASSITUDE (WEAP.I NESS)/
PALLOR SKIN/ANOREXIA (LOSS OF
APPETITE) /LOSS OF WEIGHT/MAL-
NUTR I TION/CONSTI PATI ON/ABDOM I NAL
PA I N/COLI C/HYPOTENSE/ANEM I A/
GINGIVAL LEAD LINE/TREMORS/P/
LYSIS WRIST

EXPLOS I VE/ASPHYXI ANT/NARCOS I S

ACUTE AND CUMULATIVE CENTRAL
NERVOUS SYSTEM DAMAGE/GASTRO-
INTESTINAL EFFECTS/GINGIVITIS

NARCOSIS/CUMULATIVE CENTRAL
NERVOUS SYSTEM EFFECTS/MILD
IRRITATION EYE, NOSE, THROAT

MILD IRRITATION EYE, NOSE,
THROAT/NARCOSIS

CHEMICAL ANOXIA (METABOLIC
CONVERSION TO CO)/CHRONIC LIVER
DAMAGE/CENTRAL NERVOUS SYSTEM
EFFECTS/NARCOSIS

ODOR/MODERATE IRRITATION EYE,
THROAT
                                                                 'PARA-
ACCUMULATION IN LUNGS
SKIN IRRITATION, DERMATITIS AND
SUSPECT CARCINOGEN

CUMULATIVE LIVER AND KIDNEY DAMAGE'*
BLOOD DISORDERS/MILD IRRITATION
EYE, NOSE, THROAT, LUNG

-------
              (CONT'D)
                              -4-
SUBSTANCE
OVEREXPOSURE SYMPTOMS
MONOCHLQROD!FLUOROETHANE
(FREGN-22)

NAPHTHA (COAL TAR)
NICKEL, METAL AND SOLUBLE
COMPOUNDS, AS Nl


NITRIC OXIDE
NITROGEN DIOXIDE


NUISANCE DUST


OIL MIST, MINERAL

ORTHO-DICHLOROBENZENE


OZONE


PARA-DICHLOROBENZENE


PETROLEUM DISTILLATES
(NAPHTHA)

PORTLAND CEMENT


PYRIDINE


SILICA-CRYSTALLINE

SOAPSTONE

SODIUM HYDROXIDE


SULFUR MONOCHLORIDE


SULFURIC ACID
CUMULATIVE LIVER DAMAGE
MODERATE IRRITATION EYE,
THROAT/NARCOSIS

SUSPECT CARCINOGEN/CUMULATIVE
LUNG DAMAGE/DERMATITIS

METHEMOGLOBINEMIA/CENTRAL
NERVOUS SYSTEM EFFECTS

CUMULATIVE LUNG DAMAGE  (BRONCHITIS,
EMPHYSEMA)/LUNG EDEMA

NO SIGNIFICANT ADVERSE HEALTH
EFFECTS

ACCUMULATION IN LUNGS (PNEUMONITIS)

MARKED IRRITATION EYE, NOSE,
THROAT/LIVER DAMAGE

MARKED IRRITATION RESPIRATORY
TRACT/LUNG EDEMA

CUMULATIVE SYSTEMIC TOXIC ITY/
CATARACTS

MODERATE IRRITATION NARCOSIS
NUISANCE PARTICULATE/MILD'
IRRITATION EYE AND NOSE

CUMULATIVE LIVER, KIDNEY, AND BONE
MARROW DAMAGE/CNS EFFECTS

PNEUMOCONIOSIS (SILICOSIS)

PNEUMOCONIOSIS

MARKED IRRITATION EYE, NOSE,
THROAT,, LUNGS, SKIN

MARKED IRRITATION EYE, NOSE,
THROAT, LUNG

MARKED IRRITATION EYE,, NOSE,
THROAT, SKIN, BRONCHI/DENTAL
EROSION
                            174

-------
                             -5-
              (CONT'D)
SUBSTANCE
QVEREXPQSURE SYMPTOMS
TALC (NON-ASBESTOS FORM)
1,1,2,2-TETRACHLOROETHANE

TETRACHLOROETHYLENE
TIN (INORGANIC COMPOUNDS.,
EXCEPT OXIDES)
O-TOLUIDINE
TRICHLOROETHYLENE
TRIETHYLAMINE
TURPENTINE
XYLENE (XYLOL)
ZINC CHLORIDE FUME
ZINC OXIDE FUME
PNEUMOCONIOSIS (TALCOSIS)

CUMULATIVE LIVER AND OTHER ORGAN
DAMAGE

CUMULATIVE LIVER AND CENTRAL
NERVOUS SYSTEM DAMAGE/NARCOSIS/
SUSPECT CARCINOGEN

ACUTE AND CHRONIC SYSTEMIC TOXIC I
METHEMOGLOBINEMIA/ACUTE SYSTEMIC
EFFECTS/SUSPECT CARCINOGEN

NARCOSIS/CUMULATIVE SYSTEMIC TOXIC
EFFECTS/SUSPECT CARCINOGEN

MARKED IRRITATION EYES, NOSE,
THR.OAT, LUNGS/LUNG EDEMA/CORNEAL
DAMAGE

MODERATE IRRITATION EYE, NOSE,
THROAT, BRONCHI, LUNGS, SKIN/
CUMULATIVE KIDNEY DAMAGE

MODERATE IRRITATION EYE, NOSE,
THROAT/NARCOSIS

MARKED IRRITATION EYE, NOSE, THROAT
LUNGS/ACUTE LUNG DAMAGE/SUSPECT
CARCINOGEN

ACUTE SYSTEMIC TOXICITY (METAL
FUME FEVER)
                              175

-------
176

-------
         APPENDIX D



EXAMPLE HAZARD REPORTING FORM
           177

-------
178

-------
Vhite Copy: Dept File
Veen Copy: Dept. Sends To Safety
ACTION A: To be filled out by employee
                                                          Pink Copy: Deposit in Hazard Report Box
                                                          Yellow Copy: Originator
                   HAZARD REPORTING FORM

                                3569
REPORTED TO:
REPORTED BY:
DATE:
 DESCRIPTION & LOCATION OF HAZARD:
CAUSE
RECOMMENDATION TO CORRECT OR ELIMINATE SITUATION:
SECTION B: To be filled out by Supervisor
DATE RECEIVED:
DATE OF RESPONSE TO EMPLOYEE:
        DATE ACTION COMPLETE:
ACTION TAKEN:
SUPERVISOR
                  DATE:
DEPT.SUPT.
                                                                       DATE:
                                                179

-------
180

-------
                 APPENDIX E



EPA RESPIRATORY PROTECTION PROGRAM GUIDELINE
                   181

-------
A U.S. Government Printing Office: 19I«—625-003/41110
                                                            182

-------