OPERATING ENGINEERS NATIONAL HAZMAT PROGRAM€¦ · The oxy-gasoline torch system components...

PETROGENOXY-GASOLINE TORCH

(Equipment Dismantlement)

HUMAN FACTORS ASSESSMENT

JANUARY 1999

OPERATING ENGINEERS NATIONALHAZMAT PROGRAM

INTERNATIONAL ENVIRONMENTAL TECHNOLOGY & TRAINING CENTER

PETROGENOXY-GASOLINE TORCHTABLE OF CONTENTS

ACKNOWLEDGMENTS......................................................................................iii

EXECUTIVE SUMMARY.....................................................................................iv

SECTION 1 SUMMARY Technology Description.................................................................................. 1 Key Results .................................................................................................... 4

SECTION 2 SYSTEM OPERATION.................................................................... 4

SECTION 3 HEALTH AND SAFETY EVALUATION General Health and Safety Concerns............................................................. 6 Core Issues ............................................................................................... 6 Best Management Practices ..................................................................... 8 Industrial Hygiene Monitoring......................................................................... 8 Human Factors Interface.............................................................................. 11 Technology Applicability............................................................................... 11

SECTION 4 JOB SAFETY ANALYSIS (JSA) .................................................... 13

SECTION 5 FAILURE MODES AND EFFECTS ANALYSIS (FMEA)................ 20

SECTION 6 TECHNOLOGY SAFETY DATA SHEET (TSDS) .......................... 23

SECTION 7 EMERGENCY RESPONSE/PREPAREDNESS ............................ 33

SECTION 8 REGULATORY POLICY ISSUES Core Requirements ...................................................................................... 33 Technology Specific Requirements .............................................................. 34 Special Requirements .................................................................................. 35 Best Management Practices ........................................................................ 36 Core Training Requirements ........................................................................ 36 Technology Specific Training ....................................................................... 36 Special Training ........................................................................................... 36 Best Management Practice Training ............................................................ 37

TABLE OF CONTENTS(continued)

SECTION 9 OPERATIONAL CONSIDERATIONS AND RECOMMENDATIONS ................................................................................ 37

APPENDIX A - REFERENCES ......................................................................... 44APPENDIX B - INDUSTRIAL HYGIENE DATA................................................. 45APPENDIX C - ACRONYMS............................................................................. 48

ACKNOWLEDGMENTS

The human factors assessment of the Petrogen Oxy-gasoline Torch wasconducted under support of the U.S. Department of Energy’s Federal EnergyTechnology Center, under cooperative agreement DE-FC21-95MC32260 withthe Operating Engineers National HAZMAT Program. The Operating EngineersNational HAZMAT Program would like to thank the following people for theirparticipation on the "research action team" and the professional expertise theyprovided for this assessment:

Barbara McCabe Operating Engineers National Hazmat Program

EXECUTIVE SUMMARY

The Petrogen Oxy-gasoline Torch technology was tested and is being evaluatedby Florida International University (FIU). The equipment dismantlementtechnology demonstrations are designed to evaluate technologies fordecontamination and decommissioning (D&D) work. The human factorsassessment conducted in conjunction with FIU’s evaluation of efficiency and costcovers the hazard analysis and safety evaluation for the torch. The PetrogenTorch is a commercially available technology and has been used for variousprojects at locations throughout this country.

While the torch itself does not inherently involve safety and health hazardsassociated with D&D work, the activities that are being conducted using thetechnology do. Safety and health hazards associated with the torch areaddressed in this report and although not addressed here, the specific hazardsinvolved in D&D activities need to be addressed prior to the start of the project.

The oxy-gasoline torch is a thermal method for cutting metal. The torch is fueledby a mixture of oxygen and gasoline. Any grade gasoline can be used but thesystem will not operate with kerosene, diesel fuel, or gasohol. The fuel isdelivered to the torch via a pressurized gasoline tank and an oxygen cylinder.The gasoline tank is pressurized by a built-in hand pump, or an external sourceof compressed air may be used. The gasoline and oxygen are combined in amixer in the head of the torch. The fuel, a mixture of gasoline and oxygen travelsthrough separate hoses to the tip of the torch where it is lit. After a few secondsof pre-heating, the tip of the torch becomes warm enough to vaporize thegasoline in the tip. The rapid expansion results in a high velocity stream of highlycombustible oxygen/gasoline vapor that fuels the cutting flame of the torch.Vaporization of the fuel in the tip is an endothermal process that reducesoverheating of the tip.

The oxy-gasoline torch system components include a three-gallon fuel tank,supply hoses, and cutting torch. The pressurized gasoline tank has been testedand approved by Underwriter’s Laboratory (UL). The gasoline tank consists ofthe tank, pressure gauge, filler cap assembly, hand pressure pump, and the tankgasoline shutoff valve. The tank is a 3-gallon gasoline tank that has beenmanufactured to ASME standards for unfired pressure vessels. During operationof the torch the tank is filled to about 2-inches from the top (approximately 2.5-gallons) to allow room for air which is required to pressurize the tank. Theopening of the tank is designed to accept ordinary supply nozzles found at gas-stations. The pressure gauge fits into an adapter which contains a check valvethat is designed to prevent fuel from escaping if the gauge is broken off. Thefiller cap assembly is designed with a slot at the end of the threads to permit tankpressure to be released before the cap is completely unscrewed and a pressurerelief valve that is set to release at a pressure of 35 psi. The hand pump is usedto pressurize the system. The system is pressurized to a minimum of 10 psi for

operation. The gasoline shutoff valve is a fast-flow ball check that shuts off theflow of the fuel if there is a sudden surge of fuel flow from the hose being cut,ruptured, or punctured.

The gasoline hose is a ¼-inch 2-braid hose designed specifically for gasoline.The oxygen hose is 5/16-inch 1-braid type “S”, grade “T” designed to be resistantto abrasion, fire, and oil.

Torches are hand-held or machine-mounted and consist of hose connectors, acutting lever, a high pressure oxygen valve, a gasoline valve, a mixer, the tip nut,the cutting tip, and the heating tip. The hose connectors are threaded brasstubes which connect the hoses to the base of the torch. The oxygen connectorhas a right-hand thread and the gasoline connector has a left-hand thread. Thecutting lever operates the high pressure oxygen valve which permits the oxygento enter the work head. The gasoline valve runs the entire length of the torchand controls the gasoline flow at the torch head. The mixer, which is located inthe torch head, receives the pre-heat oxygen and the gasoline and combinesthem into a fuel mixture which is then fed into the tip assembly. The cutting tip isa 2-piece assembly where the liquid fuel is vaporized, directed down to the baseof the core, and re-directed out of the tip through the flutes of the core.

During the assessment sampling was conducted for welding fume, as totalparticulate; nitrogen dioxide; carbon monoxide; carbon dioxide; and ozone andnoise. General observational techniques were conducted for ergonomics thatshowed the potential for some ergonomic stressors during setup, operation,maintenance, and decontamination of the oxy-gasoline torch. Awkward positionsthe operator has to assume to access pieces to be cut are the main ergonomicconcerns associated with the torch.

Area air sampling was conducted during operation of the oxy-gasoline torch. Theactual cutting of pipes, tubes, I-beams, etc. took approximately 5-10 minutes perpiece. Therefore, area sampling was conducted throughout the entire process toassess the potential for worker exposure during cutting operations with the oxy-gasoline torch. Personal and area samples were collected for nitrogen dioxide,carbon dioxide, and carbon monoxide. Area ozone samples were collected inthe area of the coated steel plate during cutting. All other area samples weretaken at a central location in the general work area where the cutting operationwas taking place. A forklift was periodically operated in the area to remove thepiece that was cut.

The area welding fume, as total particulate samples, showed results of 0.101mg/m3 and 01.136 mg/m3. These results are all below the OSHA PEL of 15mg/m3 and the ACGIH TLV of 5 mg/m3.

Personal and area sampling for nitrogen dioxide showed results of < 1.30,< 1.32, and < 3.33 ppm. These are below the OSHA PEL of 5 ppm (as a ceilinglevel) and the ACGIH TLV of 3 ppm, although the one sample shows a level thatis potentially at the TLV. Carbon dioxide monitoring showed results of 395.78,395.75, and 500 ppm which is below the OSHA PEL and the ACGIH TLV of 5000ppm. Carbon monoxide monitoring showed results of < 6.52, < 6.59, and < 16.67ppm which is below the OSHA PEL of 50 ppm and the ACGIH TLV of 25 ppm.Ozone monitoring showed results of <0.05 ppm which is below the OSHA PEL of0.1 ppm and the ACGIH TLV of 0.1 – 0.05 ppm, depending on the work load.

Although sampling for the contaminants discussed above did not show anyexposures above the OSHA PEL or the ACGIH TLV, fumes were visible duringthe operation of the oxy-gasoline torch. The time spent in the work area, thedistance from the actual cutting operation, and ventilation in the work area willaffect an individual worker’s exposure level. A monitoring plan will need to bedeveloped to account for the site specific conditions where the torch is beingused, including contaminants specific to the D&D project. The metal being cutwith the torch needs to be taken into consideration and contaminants specific tothe metal need to be monitored.

Area noise sampling was conducted during operation of the oxy-gasoline torch.Since the actual cutting of pipes, tubes, I-beams, etc. took approximately 5-10minutes per piece, area noise sampling was conducted throughout the entireprocess to assess the potential for worker noise exposure during cuttingoperations with the torch. Area samples were taken at a central location in thegeneral work area where the cutting operation was taking place. A forklift wasperiodically operated in the area to remove the piece that was cut.

Monitoring was conducted for 5.5 hours (327 minutes) and 2.5 hours (151minutes). Noise monitoring showed noise doses of 39.07% which would give atime-weighted average (TWA), assuming no further noise exposure for the 8-hour shift, of 83.2 dBA and a noise dose of 3.51% (TWA – 65.8 dBA). Theseresults show exposures below the OSHA “action level” of 85 dBA and the PEL of90 dBA. A projected 8-hour noise dose and resultant TWA showed the followingresults for the respective area samples: 27.1% (TWA – 80.6 dBA) and 11.12%(TWA – 74.2 dBA). These projected 8-hour noise doses also show exposuresbelow the OSHA “action level” and the PEL.

The OSHA “action level” is a noise dose of 50% or an 8-hour TWA of 85 dBAand the PEL for noise is a 100% dose or an 8-hour TWA of 90 dBA. The levels ofexposure recorded during the testing demonstration show noise has the potentialto be a concern. Operators may need to be included in a hearing conservationprogram based on the noise levels specific to the location where the torch isbeing used. Differences in noise exposure will be based on the location of theworker in relation to the cutting operation and the amount of time the workerspends there. A sampling plan will need to be developed to address the site

specific conditions where the thermal cutting operation takes place. A samplingplan should also take into consideration the work environment since the noiselevels may increase or decrease based on the construction of the enclosurewhere the cutting operation is taking place.

Recommendations for improved worker safety and health during use of the Oxy-gasoline Torch include: 1. keeping all hoses and lines as orderly as possible incompliance with good housekeeping requirements; 2. ergonomic training toinclude techniques in lifting, bending, stooping, twisting, etc.; 3. assessment ofheat stress to include the extra heat load created by the sparks, flame, and hotmetal; 4. use of safety glasses, goggles, or other appropriate eye protectionunder the welding helmet; 5. the use of a welding helmet with the correct filter inplace; 6. using only a chipping hammer or chisel to chip slag; 7. avoidingtouching cement or stone surfaces with the torch; 8. the use of puncture resistantgloves when handling cut metal pieces; 9. the use of gloves appropriate for hotwork when handling hot metal pieces; 10. adequate ventilation in the area wherethe cutting operation is taking place; and 11. requiring proper handling, storage,and usage of compressed gas cylinders and gasoline.

PETROGENOxy-gasoline TorchHuman Factors Assessment


SECTION 1 - SUMMARY

TECHNOLOGY DESCRIPTION

The Petrogen Oxy-gasoline Torch technology was tested and is being evaluatedby Florida International University (FIU). The equipment dismantlementtechnology demonstrations are designed to evaluate technologies fordecontamination and decommissioning (D&D) work. The human factorsassessment conducted in conjunction with FIU’s evaluation of efficiency and costcovers the hazard analysis and safety evaluation for the torch. The Petrogenoxy-gasoline torch is a commercially available technology and has been used forvarious projects at locations throughout this country.

While the torch itself does not inherently involve safety and health hazardsassociated with D&D work, the activities that are being conducted using thetechnology do. Safety and health hazards associated with the oxy-gasoline torchare addressed in this report and although not addressed here, the specifichazards involved in D&D activities need to be addressed prior to the start of theproject.

D&D activities within the Department of Energy (DOE) require that personnelhave access to all areas of structures, some of which are over 40 years old andmany are deteriorated and lack any preventive maintenance over the years.D&D activities and the associated hazards to workers involve not only thecontaminants specific to the environment but general construction safety andhealth. A safety and health program specific for the project needs to bedeveloped and should include but not be limited to:

• responsibilities for safety and health, including reporting hazards andaccidents, obtaining and using personal protective equipment, conductingsafety inspections, maintaining a safe and healthful work environment,enforcing safety and health requirements

• procedures for conducting safety and health orientation and periodic trainingsessions

• procedures for reporting accidents• procedures for obtaining first aid and emergency treatment• procedures for reporting work hazards

• procedures for testing and certifying equipment• job-site sanitation• the use and purpose of equipment lockout and confined space entry• the technical requirements (personal protective equipment, hazardous

materials, welding and cutting, electrical, material handling, rigging,pressurized systems, scaffolding, etc.)

Workers must be trained in accordance with all applicable OSHA safety andhealth regulations and only workers trained and certified, as applicable, shouldbe allowed to perform operations and/or operate equipment used during the D&Dactivities. For example, only workers trained in fall protection in accordance withOSHA 29 CFR 1926.503 are allowed to work from a height, only operatorstrained on forklifts in accordance with OSHA 29 CFR 1910.178 are allowed tooperate a forklift, and functions such as welding and cutting and the operation ofheavy equipment should only be done by workers trained and/or certified toperform them.

Inspection programs and preventive maintenance programs need to be in placeto assure all equipment is in good working condition and removed if it is not. Inaddition, job pre-planning is essential to assure all work to be performed will bedone so in a safe manner.

Hoisting and rigging activities which often account for accidents with injuriesand/or fatalities, will be an integral part of all D&D projects. Considerations forhoisting and rigging during a D&D project should include but not be limited to:

• All hoisting and rigging activities must be conducted in accordance withOSHA 29 CFR 1926 Subpart N Cranes, Derricks, Hoists, Elevators, andConveyors.

• Only workers with the appropriate qualifications and training be allowed toperform hoisting and rigging functions during the D&D project.

• All workers, including supervisory personnel, should review and followestablished procedures and regulations.

• When proper procedures, planning, or equipment is not available for the job,work should be stopped.

• Only manufacturer-approved or properly engineered equipment should beused and it should be used appropriately.

• Preventive maintenance activities should be scheduled and the process forperformance reviewed for adequacy.

• Hoisting and rigging activities, including the use of forklifts, should be properlyplanned before work begins to ensure proper procedures and equipment areavailable and the hazards are identified.

• Workers, including supervisory personnel, should familiarize themselves withthe equipment, work area hazards, transportation routes, and the layout of thefacility before starting the job.

• Before beginning hoisting and rigging activities, including the use of a forklift,assure the center of gravity and weight of the load has been properlycalculated.

• Assure workers have training and experience directly applicable to the type ofactivities to be conducted.

• Inspect all chain, wire rope, slings, etc. to assure it is in good workingcondition before the hoisting and rigging work is started.

Another frequent cause of accidents with injuries is the use of forklifts.Considerations for the use of forklifts during a D&D project should include but notbe limited to:

• All forklift activities must be conducted in accordance with OSHA 29 CFR1910.178 Powered Industrial Trucks.

• Only trained and authorized operators shall be permitted to operate theforklift.

• Modifications to the forklift should be approved by the forklift manufacturer. Ifthe modifications affect the capacity and safe operation of the forklift, theymust be approved in writing by the forklift manufacturer and capacity,operation, and maintenance instruction plates, tags, or decals shall bechanged accordingly.

• Modification designs should be approved by a professional engineer. Anywelding or modifications should be done by a certified welder and inspectedin accordance with ASTM guidelines. All parts used, such as bolts, must berated for the load.

• No one shall be allowed to stand or pass under an elevated portion of theforklift, whether loaded or empty.

• The forklift must not be left unattended with a suspended load. If theoperator of the forklift is within 25 ft. and has a view of the forklift, the loadengaging means must be fully lowered, controls neutralized, and the brakesset to prevent movement. If the operator is greater than 25 ft. or does nothave a view of the forklift, the load engaging means shall be fully lowered,controls neutralized, power shut off, and brakes set.

• The forklift must be rated for the load.• All hoisting and rigging equipment must be rated for the load.• It needs to be assured that the forklift is properly equipped with a working

backup alarm, beacon light, seat belt, and fire extinguisher.• A maintenance and inspection program should be in place to assure that any

forklift that is not in safe operating condition is removed from service.

The oxy-gasoline torch is a thermal method for cutting metal. The torch is fueledby a mixture of oxygen and gasoline. The fuel is delivered to the torch via apressurized gasoline tank and an oxygen cylinder. The gasoline tank ispressurized by a built-in hand pump, or an external source of compressed airmay be used. The gasoline and oxygen are combined in a mixer in the head ofthe torch. The fuel, a mixture of gasoline and oxygen travels through separate

hoses to the tip of the torch where it is lit. After a few seconds of pre-heating, thetip of the torch becomes warm enough to vaporize the gasoline in the tip. Therapid expansion results in a high velocity stream of highly combustibleoxygen/gasoline vapor that fuels the cutting flame or the torch. Vaporization ofthe fuel in the tip is an endothermal process that reduces overheating of the tip.

The pressurized gasoline tank has been tested and approved by Underwriter’sLaboratory (UL). Safety features that have been built into the gasoline tankinclude a pressure relief valve built into the fill cap and a check valve inside thetank that stops the flow of gasoline if the hose ruptures and a sudden surge inthe flow is detected.

KEY RESULTS

The safety and health evaluation during the testing demonstration focused ontwo types of potential exposure: welding fume, as total particulate and noise.Smoke and fume was visible during operation of the oxy-gasoline torch but airsampling results showed values below the Occupational Safety and HealthAdministration (OSHA) permissible exposure limit (PEL) and the AmericanConference of Governmental Industrial Hygienists (ACGIH) threshold limit value(TLV). This will be discussed in greater detail in the Industrial HygieneMonitoring section of this report. Noise exposure ranged from below to near the"action level". This will also be discussed in greater detail in the IndustrialHygiene section of this report. Further testing for each of these exposures isrecommended because the environment where the technology is being used, thetime the worker spends in the area, and the distance the worker is from theoperational area may cause exposures to be higher or lower. Air sampling andnoise monitoring will be required in all operational settings. Other safety andhealth hazards found were ergonomics, heat stress, tripping hazards, firehazards, burn hazards, physical eye hazards and exposure to ultraviolet light,lockout/tagout, hazards associated with the use of compressed gases, andhazards associated with the use of gasoline.

SECTION 2 - SYSTEM OPERATION

The oxy-gasoline torch is a thermal method for cutting metal. The torch is fueledby a mixture of oxygen and gasoline. Any grade gasoline can be used but thesystem will not operate with kerosene, diesel fuel, or gasohol. The fuel isdelivered to the torch via a hose connected to a pressurized gasoline tank and anoxygen cylinder. The gasoline tank is pressurized by a built-in hand pump, or anexternal source of compressed air may be used. The gasoline and oxygen arecombined in a mixer in the head of the torch. The fuel, a mixture of gasoline andoxygen, travels through separate hoses to the tip of the torch where it is lit. Aftera few seconds of pre-heating, the tip of the torch becomes warm enough tovaporize the gasoline in the tip. The rapid expansion results in a high velocitystream of highly combustible oxygen/gasoline vapor that fuels the cutting flame

of the torch. Vaporization of the fuel in the tip is an endothermal process thatreduces overheating of the tip.

The oxy-gasoline torch system components include a three-gallon fuel tank,supply hoses, and cutting torch. The pressurized gasoline tank has been testedand approved by Underwriter’s Laboratory (UL). The gasoline tank consists ofthe tank, pressure gauge, filler cap assembly, hand pressure pump, and the tank

gasoline shutoff valve. The tank is a 3-gallon gasoline tank that has beenmanufactured to ASME standards forunfired pressure vessels. During operationof the torch the tank is filled to about 2-inches from the top (approximately 2.5-gallons) to allow room for air which isrequired to pressurize the tank. Theopening of the tank is designed to acceptordinary supply nozzles found at gas-

stations. The pressure gauge fits into an adapter which contains a check valvethat is designed to prevent fuel from escaping if the gauge is broken off. Thefiller cap assembly is designed with a slot at the end of the threads to permit tankpressure to be released before the cap is completely unscrewed and a pressurerelief valve that is set to release at a pressure of 35psi. The hand pump is used to pressurize thesystem. The system is pressurized to a minimum of10 psi for operation. The gasoline shutoff valve is afast-flow ball check that shuts off the flow of the fuelif there is a sudden surge of fuel flow from the hosebeing cut, ruptured, or punctured.

The gasoline hose is a ¼-inch 2-braid hosedesigned specifically for gasoline. The oxygen hoseis 5/16-inch 1-braid type “S”, grade “T” designed tobe resistant to abrasion, fire, and oil.

Torches are hand-held or machine-mounted andconsist of hose connectors, a cutting lever, a highpressure oxygen valve, a gasoline valve, a mixer, the tip nut, the cutting tip, andthe heating tip. The hose connectors are threaded brass tubes which connectthe hoses to the base of the torch. The oxygen connector has a right-handthread and the gasoline connector has a left-hand thread. The cutting leveroperates the high pressure oxygen valve which permits the oxygen to enter thework head. The gasoline valve runs the entire length of the torch and controlsthe gasoline flow at the torch head. The mixer which is located in the torch headreceives the pre-heat oxygen and the gasoline and combines them into a fuelmixture which is then fed into the tip assembly. The cutting tip is a 2-piece

Figure 1. Hand-held oxy-gasoline torch.

Figure 2. 2-piece cutting tipassembly.

assembly where the liquid fuel is vaporized, directed down to the base of thecore, and re-directed out of the tip through the flutes of the core.

SECTION 3 - HEALTH AND SAFETY EVALUATION

GENERAL SAFETY AND HEALTH CONCERNS

Personnel where the oxy-gasoline torch technology is being used need to beconcerned with two categories of safety and health issues. Core issues arethose that are based on current safety and health regulatory requirements. Bestmanagement practices are related to issues that are not based on current safetyand health regulations, but are key elements in preventing worker injury andillness on the job.

Safety and health issues of concern with the oxy-gasoline technology included:

Core Issues:

♦ Tripping Hazards - The hoses, while necessary for the operation of theequipment, can become tripping hazards. Stringent housekeeping must beaddressed.

♦ Pinch Points - The potential exists for the operator to have his/herfingers/hand injured moving gas cylinders if caught between two stationaryobjects.

♦ Lockout/Tagout - The user of the technology will need to develop alockout/tagout program to assure there is not an accidental release of energyduring maintenance/repair activities.

♦ Noise - The operator and workers in the area were subjected to noise levelsranging from below to near the OSHA “action level”. The "action level" is 85dBA for an 8-hour work shift. The level of exposure will be influenced by theamount of time the worker spends in the area where the cutting operation istaking place and the distance the operator is from the work. Therefore, noisemay be a concern under certain circumstances and will be discussed ingreater detail in the Industrial Hygiene section of this report.

♦ Fume - Visible smoke and fumes were generated during operation of thetorch. Air sampling results showed a level of welding fume, as totalparticulate less than the OSHA PEL and the ACGIH TLV. The PEL is 15mg/m3 and the TLV is 5 mg/m3. Welding fume, however, may be a concernunder certain operational conditions and a sampling plan to address these ona job-by-job site-by-site basis will need to be developed. Other contaminantssampled during the testing demonstration were carbon monoxide, carbon

dioxide, nitrogen dioxide, and ozone. These will be discussed in detail in theIndustrial Hygiene Monitoring Section of this report.

Sparks and slag are of concern during cutting operations using the oxy-gasoline torch. They are spread throughout the area during cutting andtherefore, have the potential to create additional airborne contaminants, suchas metal particulate. They also present a fire, burn, and physical eye hazard.

♦ Fire hazards – Heat, sparks, or flame present during thermal cutting has thepotential to cause a fire hazard. When fire hazards present in the areacannot be moved, then guards must be set up to contain heat, sparks, andslag.

♦ Gasoline – By definition, gasoline is considered a flammable liquid.Flammable liquids present hazards to the worker and the environment wherethey are used. Appropriate precautions need to be taken for storage,handling, and use.

♦ Ventilation – Adequate breathing air must be provided for in thermal cuttingoperations. Adequate ventilation will depend on the dimensions and layout ofthe work area, number of cutting operations, contaminants in the area and theallowable level for each, and the natural air flow in the area. Mechanicalventilation and, as a last resort, respirators may be needed to provideadequate breathing air and protect workers.

♦ PPE – The sparks and spatter present severe physical eye hazards. Thewelding helmet will protect the eyes from sparks and spatter that strikedirectly against it but they are not intended to protect against those thatricochet under the helmet. Safety glasses with side shields, goggles, or otherappropriate eye protection must also be worn to protect against these impacthazards.

The oxy-gasoline torch produces ultraviolet light which can damage the eyesin the form of a “flash” or after long term exposure, cataracts. Properprotection for the eyes while performing cutting operations with the oxy-gasoline torch is the welding helmet with the correct filter in place. Filterdarkness needs to chosen in compliance with OSHA 29 CFR Subpart QWelding, Cutting, Brazing. Other workers in the area during cuttingoperations need to wear safety glasses with an appropriate darkness rating.

The sparks, spatter, and ultraviolet light may cause skin burns. Protectiveclothing needs to provide sufficient coverage and be made of flame-retardantmaterials to minimize skin burns. Covering all parts of the body isrecommended to prevent flash burn from ultraviolet and infrared rays.

Best Management Practices:

♦ Heat Stress - The operator may be subjected to an increase in heat stressdue to the heat generated during thermal cutting operations. Sparks, flame,slag, and hot metal will add to the heat load. The need to utilize personalprotective equipment (PPE), flame-resistant garments, will also add to theheat load. The user will need to develop a heat stress program for theenvironment in which the technology is being used, taking into considerationany necessary PPE, ambient temperatures, etc.

♦ Ergonomics - The worker is subjected to ergonomic stressors that need to betaken into consideration, such as stooping, bending, twisting, kneeling, lifting,and static postures.

♦ Communication - Due to the noise generated by the technology, at times,during operation, communication may be difficult. Personnel working in thearea should be familiar with and use hand signals when needed.

INDUSTRIAL HYGIENE MONITORING

During this testing demonstration with the oxy-gasoline torch, sampling wasconducted for welding fume, as total particulate, carbon monoxide, carbondioxide, nitrogen dioxide, ozone, and noise. In addition, the wet-bulb globetemperature was monitored to evaluate heat stress. Observational evaluationwas conducted for ergonomics.

Through general observational techniques the potential for ergonomic problemswas evaluated during the testing demonstration. The potential exists for upperand lower back, arm, and leg stress and/or injuries due to bending, twisting, andlifting associated with setup, operation, maintenance, and decontamination.

During cutting operations, many ergonomic stressors are placed on the bodyfrom awkward and static postures. There is also concern for the manual forceand repetitive motions that may be required. In order to make a cut, the workershad to get into tight places by twisting themselves into place or by propping theirbodies into awkward positions. Stresses occur from holding the head and armsin unnatural, fixed positions for long amounts of time. This often results instiffness and soreness in the body. Overhead work can result in a conditionknow as shoulder tendonitis (inflammation of the tendons of the shoulder) andthere is concern for the stress placed on the back from bending to cut pieceslocated on ground level.

Pre-planning to place the operator in the best position for ergonomics and safetyshould be done before operations begin and periodically as the job progresses.Workers should not place themselves in positions that cause the body discomfort

but since many times these awkward postures are unavoidable, workers should,at the first sign of soreness, stop and stretch.

Heat stress parameters were monitored using a Quest QuestTemp°15 HeatStress Monitor. The wet-bulb globe temperature was used to determine thework/rest regimen in accordance with the ACGIH recommendations. The wet-bulb globe temperature was adjusted for the type of clothing, including PPE, thatthe worker was wearing, in accordance with ACGIH guidelines.

While heat stress will be increased when wearing PPE, the overall heat stressresponse will vary from worker to worker. Each situation in which the currenttechnology is used will need to be evaluated for the heat stress potential, takinginto consideration the wet-bulb globe temperature, PPE in use, physical conditionof the worker, and worker acclimatization.

Air sampling for welding fume, as total particulate was conducted with a samplingtrain consisting of an MSA Escort Elf air-sampling pump and a pre-weighedcassette with a5 µg PVC filter. Pre- and post- sampling calibration was accomplished using aBIOS International DryCal DC1 primary calibration system. The sampling wasconducted and analyzed in accordance with National Institute of OccupationalSafety and Health (NIOSH) Method 0500. Samples were analyzed by alaboratory accredited by the American Industrial Hygiene Association (AIHA).Carbon dioxide, carbon monoxide, and nitrogen dioxide were monitored usingDräger direct reading diffusion tubes and ozone was monitored using a Drägershort-term measurement tube.

Area air sampling was conducted during operation of the oxy-gasoline torch. Theactual cutting of pipes, tubes, I-beams, etc. took approximately 5-10 minutes perpiece. Therefore, area sampling was conducted throughout the entire process toassess the potential for worker exposure during cutting operations with the oxy-gasoline torch. Personal and area samples were collected for nitrogen dioxide,carbon dioxide, and carbon monoxide. Area ozone samples were collected inthe area of the coated steel plate during cutting. All other area samples weretaken at a central location in the general work area where the cutting operationwas taking place. A forklift was periodically operated in the area to remove thepiece that was cut.

The area welding fume, as total particulate samples showed results of 0.101mg/m3 and 1.136 mg/m3. These results are all below the OSHA PEL of 15mg/m3 and the ACGIH TLV of 5 mg/m3. (See Appendix B for sampling data).

Personal and area sampling for nitrogen dioxide showed results of < 1.30, <1.32, and < 3.33 ppm. These are below the OSHA PEL of 5 ppm (as a ceilinglevel) and the ACGIH TLV of 3 ppm, although the one sample shows a level thatis potentially at the TLV. Carbon dioxide monitoring showed results of 395.78,

395.75, and 500 ppm which is below the OSHA PEL and the ACGIH TLV of 5000ppm. Carbon monoxide monitoring showed results of < 6.52, < 6.59, and < 16.67ppm which is below the OSHA PEL of 50 ppm and the ACGIH TLV of 25 ppm.Ozone monitoring showed results of<0.05 ppm which is below the OSHA PEL of 0.1 ppm and the ACGIH TLV of0.1 – 0.05 ppm, depending on the work load.

Although sampling for the contaminants discussed above did not show anyexposures above the OSHA PEL or the ACGIH TLV, fumes were visible duringthe operation of the oxy-gasoline torch. The time spent in the work area, thedistance from the actual cutting operation, and ventilation in the work area willaffect an individual worker’s exposure level. A monitoring plan will need to bedeveloped to account for the site specific conditions where the torch is beingused, including contaminants specific to the D&D project. The metal being cutwith the torch needs to be taken into consideration and contaminants specific tothe metal need to be monitored.

Area noise sampling was conducted during operation of the oxy-gasoline torch.Since the actual cutting of pipes, tubes, I-beams, etc. took approximately 5-10minutes per piece, area noise sampling was conducted throughout the entireprocess to assess the potential for worker noise exposure during cuttingoperations with the torch. Area samples were taken at a central location in thegeneral work area where the cutting operation was taking place. A forklift wasperiodically operated in the area to remove the piece that was cut. Area noisesampling was conducted using Metrosonics db-3100 noise dosimeters.Calibration was conducted pre-and-post monitoring using a Metrosonics CL 304acoustical calibrator.

Monitoring was conducted for 5.5 hours (327 minutes) and 2.5 hours (151minutes). Noise monitoring showed noise doses of 39.07% which would give atime-weighted average (TWA), assuming no further noise exposure for the 8-hour shift, of 83.2 dBA and a noise dose of 3.51% (TWA – 65.8 dBA). Theseresults show exposures below the OSHA “action level” of 85 dBA and the PEL of90 dBA. A projected 8-hour noise dose and resultant TWA showed the followingresults for the respective area samples: 27.1% (TWA – 80.6 dBA) and 11.12%(TWA – 74.2 dBA). These projected 8-hour noise doses also show exposuresbelow the OSHA “action level” and the PEL.

During the monitoring periods, the noise levels were averaged for each one-minute period and then an overall average was calculated. This gave anaverage exposure level of 80.6 dB and 74.2 dB for the respective area samples.The maximum sound levels observed during monitoring were 107.1 dB and108.3 dB.

The OSHA “action level” is a noise dose of 50% or an 8-hour TWA of 85 dBAand the PEL for noise is a 100% dose or an 8-hour TWA of 90 dBA. The levels of

exposure recorded during the testing demonstration show noise has the potentialto be a concern. Operators may need to be included in a hearing conservationprogram based on the noise levels specific to the location where the torch isbeing used. Differences in noise exposure will be based on the location of theworker in relation to the cutting operation and the amount of time the workerspends there. A sampling plan will need to be developed to address the sitespecific conditions where the thermal cutting operation takes place. A samplingplan should also take into consideration the work environment since the noiselevels may increase or decrease based on the construction of the enclosurewhere the cutting operation is taking place.

HUMAN FACTORS INTERFACE

Workers using a technology for cutting pieces during D&D activities mayencounter a variety of contaminants when working in a hazardous waste siteenvironment. This may include contaminants associated with the pieces beingdismantled, the material the pieces are constructed of, or contamination inherentin the environment where the pieces are located. Therefore, different levels ofPPE, such as level A, B, C, or D or different types as PPE such as Anti-C, forradiation contamination may need to be utilized. These contaminants should beidentified by the site characterization prior to the start of the D&D project.

The level of protection being utilized has the potential to cause several humanfactors interface problems. These may include, but not be limited to, visibility,manual dexterity, tactile sensation, an increase in heat stress, and an overallincrease in physical stress.

An additional concern with thermal cutting is the need for the worker to utilizeflame-retardant PPE. This will need to be taken into consideration whenchoosing the PPE to protect against other types of contamination.

TECHNOLOGY APPLICABILITY

There was visible smoke and fume during the cutting operation but the airsampling results showed sampling values below the OSHA PELs and the ACGIHTLVs. A sampling plan will need to be developed to assess contaminants undersite specific conditions.

The torch and all of the system components will need to be disassembled to bedecontaminated. This will not necessarily guarantee that decontamination willbe complete. If total decontamination is not possible, the equipment and/or partsof the equipment may need to be considered a consumable.

SECTION 4 - JOB SAFETY ANALYSIS

JOB SAFETY ANALYSISPETROGEN

Oxy-gasoline Torch(Equipment Dismantlement)

HAZARD CORRECTIVE ACTIONSETUP AND TEAR DOWN

* Pinch Points * Use of hand protection* Use of proper hand tools for the job

* Slips/Trips/Falls * Awareness of the specific hazards* Organization of materials (housekeeping)* Walking around areas that are congested whenpossible* Walking around tripping hazards when possible* Marking, isolating, and/or bunching togethertripping hazards

* Stuck by (gas cylinder/parts) * Assure gas cylinder is properly secured invertical position and cannot fall* Do not allow cylinder to be dropped or knockedover* Be sure valve protection cap is secure whenmoving cylinder or when cylinders are beingstored* Stand so the cylinder is between you and theregulator; never stand in front of the regulatorwhen opening

HAZARD CORRECTIVE ACTIONSETUP AND TEAR DOWN (CONTINUED)

* Exposure to fuel gas (gasoline) * Do not pour gasoline from one container toanother* Assure proper precautions are taken whendispensing gasoline into the tank; workers shouldtake care not to get the gasoline on themselvesor their clothing; wear PPE as appropriate

* Fire/explosion hazard * Assure there is no oil, grease, or damagedparts on the regulator or valves (of oxygencylinder); if there is, do not use* Never use any rags with oil or grease on themto wipe the cylinder, valve, or regulator of theoxygen cylinder* Assure all safety features on the gasoline tankare in good condition and working properlybefore filling the tank* Pressurize the gasoline tank to 10-20 psig; thepressure gauge is marked in red above 20 psig;do not allow the gauge to read in the red area

* Muscular/Back Injury * Ergonomic training including safe liftingtechniques

CUTTING (OPERATION)* Muscular/Back Injury (fromstooping, bending, awkwardpositions)

* Ergonomics training* Pre-planning job

* Slips/Trips/Falls * Awareness of site specific hazards (cords,umbilical line, etc.)* Job site organization of materials(housekeeping)* Walk around hazards when possible* Marking, isolating, and/or bunching togethertripping hazards

* Pinch Points * Assure worker training in the proper operationof the oxy-gasoline torch and use of compressedgas cylinders

HAZARD CORRECTIVE ACTIONCUTTING (OPERATION) (CONTINUED)

* Eye hazard/struck by (sparking) * Wear safety glasses with side shields, goggles,or other appropriate eye protection under thewelding helmet

* Eye hazard (ultraviolet/infraredlight)

* Wear a welding helmet with the correct filter inplace; filter darkness needs to be selected inaccordance with OSHA 29 CFR Subpart QWelding, Cutting, Brazing* Workers in the area where the cutting operationis taking place need to wear safety glasses withan appropriate darkness rating* Assure all filters and lenses meet the test fortransmission of radiant energy prescribed inANSI Z87.1 Practice for Occupational andEducational Eye and Face Protection* Wear dark clothing to reduce reflection underthe welding helmet

* Burn hazards (sparks, spatter,radiation)

* Use appropriate flame-resistant PPE , asrequired (gauntlet gloves, jacket, apron, etc.)* Cover all parts of the body to protect againstultraviolet and infrared ray flash burn* Do not wear clothing that can melt or can causesevere burn due to sparks that may lodge inrolled-up sleeves, pockets of clothing, or pantcuffs* Point the tip away from yourself, other people inthe area, equipment, and any combustiblematerials when lighting the torch* Never light the torch with anything other than astriker designed for that purpose* Pre-planning to allow cut to be made as safelyas possible and direct sparking away fromworker when possible* Assure all workers in the area are aware ofwhere a cut has been made and the metal is hot* Use gloves for hot work to handle hot pieces ofmetal

HAZARD CORRECTIVE ACTIONCUTTING (OPERATION) (C0NTINUED)

* Fire/Explosion hazards * Assure workers are aware of all combustibles inthe area before the cutting operation begins* Move as many of the combustibles away fromthe area as possible* If combustibles/fire hazards cannot be moved,set up guards to contain heat, sparks, and flame* Assure no grease or oil is present on the PPEor work clothes of the workers in the area* Assure fire watch is present, as required*Have portable fire extinguishers and/or otherappropriate fire protection equipment available inthe area, and assure workers are trained, asrequired* Assure no flammables are in or near the areawhere cutting is being done* Special precautions on drums, tanks, andclosed containers – have they held flammablematerials?* Assure all hoses and fittings are inspected forleaks before use* Use backflash arrester on the oxygen line* Assure all safety features on the gasoline tankare in good condition and operational* Fill the gasoline tank outside of the work areaand bring only closed tank into the area* Turn the oxygen on first, can get a flow of liquidgas

* Cut/Laceration hazards * Use puncture resistant gloves whenhandling metal pieces that have been cut


* Struck by hazards * Aim torch away from cement or stone surfaces;moisture within these materials could cause themto explode when they reach a certaintemperature* Only use chipping hammers and chisels whichare designed for slag removal* Always wear safety glasses with side shieldswhen chipping slag; a face shield may also berequired* Workers must always be aware of where thecutting is being done; do not allow any one underthe area where cuts are made on elevatedpieces

* Noise * Use engineering controls, as required* Use administrative controls, as required* Use proper hearing protection devices, asrequired

* Heat stress * Have a heat stress program in place* Assure the heat stress program accounts forthe added heat load from the thermal cuttingprocess* Use cooling devices, as required


* Exposure to Contaminants * Assure workers are aware of the hazards in thearea where they are using the torch* Use of proper PPE, including respiratoryprotection* Worker training to use good work practices thatwill enable worker to avoid contact with anycontaminated surfaces, i.e. the floor, walls, otherstructures in the area* Only perform cutting operations in wellventilated areas* Check hoses, regulator, and valves for leaksbefore use* Keep cylinder wrench, if one is required, oncylinder valve so can quickly be turned off* Evaluation of possible hazards from metalbeing cut, coatings on the metal, contaminationinherent to the area, etc. be made before thecutting process begins* Assure all safety devices on the gasoline tankare in good condition and operational beforeusing the tank* When igniting the torch, the gasoline valve isopened until a spray comes out; the workershould never point the head of the torch athimself/herself or any other person; this couldresult in exposure, in particular dermal exposureto the gasoline* When igniting the torch, the striker is to be heldto one side but close to the tip of the torch; notonly will this keep the striker from getting wetwith gasoline but it will also keep the worker’shand/arm from being exposed to the gasoline

HAZARD CORRECTIVE ACTION

GENERAL MAINTENANCE* Ergonomics/Bending/Kneeling/Lifting

* Use proper lifting techniques* Ergonomic training to include proper liftingtechniques

* Exposure to contaminant * Wear proper PPE, including respiratoryprotection* Have something to sit or kneel on so do nothave additional personnel exposure from sittingor kneeling on contaminated surface* Assure the torch is disconnected from theoxygen and gasoline before any work isperformed

* Pinch Points * Use of hand protection* Use of hand tools appropriate for the job

* Slips/Trips/Falls * Awareness of the specific hazards* Organization of materials (housekeeping)* Walking around areas that are congested whenpossible* Walking around tripping hazards, whenpossible

SECTION 5 - FAILURE MODE AND EFFECTS ANALYSIS

FAILURE MODE AND EFFECTS ANALYSISPETROGEN

Oxy-gasoline Torch(Equipment Dismantlement)

FAILURE MODE EFFECT* Barrier placed between cutting operationand combustibles fails or is inappropriate

* Fire with potential to cause burns andrelated fire injuries to workers

* Oxygen cylinder/valve/regulator fails * Injury to workers from being struck byprojectiles from cylinder exploding, orfrom cylinder, valve, or regulator itself* Injuries to workers from fire/explosiondue to materials in area (oil, grease)* Workers exposed to oxygen enrichedatmosphere

* Relief valve on regulator fails * Low pressure side of regulator builds uppressure with resultant rupture; potentialfor injury to workers from regulator orpieces of regulator becoming projectiles

* Hose ruptures/leaks/disconnects (onoxygen cylinder)

* Potential for worker exposure to oxygenenriched atmosphere* Potential for fire or explosion withresultant injuries to workers

* Flash arrestor on oxygen hose fails (ifone is present)

* Potential for fire or explosion withresultant injuries to workers fromflashback reaching upstream equipment

* Oxygen hose not purged of possiblegasoline vapors

* Potential for flashback resulting in fire orexplosion resulting in injuries to workers

* Oxygen not opened first / Gasoline notturned off first

* Potential for workers to be exposed toliquid gasoline

FAILURE MODE EFFECT* Gasoline tank shutoff valve fails * The gasoline will flow freely if the hose is

damaged/ruptured/cut/punctured –potential for fire/explosion with injury toworkers and/or worker exposure togasoline

* Torch operated with less than 10 psig ofpressure in the tank

* Potential for fast-flow check valve to notstop the gasoline flow, if required; canlead to the gasoline flowing freely if thehose is damaged/ruptured/cut/punctured;potential for fire/explosion with injury toworkers and/or worker exposure togasoline

*O-ring under packing bushing in highpressure oxygen valve fails

* Potential for worker exposure toenriched oxygen atmosphere

* Compression fitting on butt face notseated properly

* Gasoline leaks at compression fittingwith potential for fire/explosion with injuryto workers and/or worker exposure togasoline

* The connector on the gasoline hose isnot tight in the butt

* Gasoline leaks at hose connector withpotential for fire/explosion with injury toworkers and/or worker exposure togasoline

*O-ring in torch handle fails * Gasoline leaks at the weep hole on thetorch handle with potential forfire/explosion with injury to workers and/orworker exposure to gasoline

*External o-ring or internal packing o-ringon high pressure oxygen valve fails

* Oxygen leaks at high pressure oxygenvalve with potential for fire/explosion withinjury to workers and/or worker exposureto oxygen enriched atmosphere

* Packing nut not tight on torch * Oxygen leaks at pre-heat oxygen valvewith potential for fire/explosion with injuryto workers and/or worker exposure tooxygen enriched atmosphere

* Bad seating inside torch head betweenthe tip nut, tip, mixer, and torch head

* Gasoline leaks at the tip nut withpotential for fire/explosion with injury toworkers and/or worker exposure togasoline

* Packing nut on tank not tight * Gasoline leaks at the shutoff valvepacking nut with potential forfire/explosion with injury to workers and/orworker exposure to gasoline

FAILURE MODE EFFECT* Internal valve seat on tank is faulty * Gasoline leaks at the outlet of the

shutoff valve, even with the handwheelshut - potential for fire/explosion withinjury to workers and/or worker exposureto gasoline

SECTION 6 - TECHNOLOGY SAFETY DATA SHEET

TECHNOLOGY SAFETY DATA SHEETPETROGEN

Oxy-gasoline Torch


SECTION 1: TECHNOLOGY IDENTITYEmergency Contact:

Milt Heft, General Manager

(510)237-7274Information Contact:

Milt Heft, General Manager

(510)237-7274

Manufacturer’s Name and Address:

Petrogen International, Ltd.P.O. Box 1592Richmond, CA 94802

Date Prepared:

Other Names:

Oxy-gasoline Cutting TorchOxy-gasoline Safety Torch

Signature of Preparer:

Operating Engineers National HazmatProgram1293 Airport Road, Beaver, WV 25813,phone 304-253-8674, fax 304-253-7758

Under cooperative agreement DE-FC21-95 MC 32260

SECTION 2: PROCESS DESCRIPTIONThe oxy-gasoline torch is a thermal method for cutting metal. The torch is fueled by amixture of oxygen and gasoline. Any grade gasoline can be used but the system willnot operate with kerosene, diesel fuel, or gasohol. The fuel is delivered to the torchvia a hose connected to a pressurized gasoline tank and an oxygen cylinder. Thegasoline tank is pressurized by a built-in hand pump, or an external source ofcompressed air may be used. The gasoline and oxygen are combined in a mixer inthe head of the torch. The fuel, a mixture of gasoline and oxygen, travels throughseparate hoses to the tip of the torch where it is lit. After a few seconds of pre-heating, the tip of the torch becomes warm enough to vaporize the gasoline in the tip.The rapid expansion results in a high velocity stream of highly combustibleoxygen/gasoline vapor that fuels the cutting flame of the torch. Vaporization of thefuel in the tip is an endothermal process that reduces overheating of the tip.

The oxy-gasoline torch system components include a three-gallon fuel tank, supplyhoses, and cutting torch. The pressurized gasoline tank has been tested andapproved by Underwriter’s Laboratory (UL). The gasoline tank consists of the tank,pressure gauge, filler cap assembly, hand pressure pump, and the tank gasolineshutoff valve. The tank is a 3-gallon gasoline tank that has been manufactured toASME standards for unfired pressure vessels. During operation of the torch the tankis filled to about 2-inches from the top (approximately 2.5-gallons) to allow room forair which is required to pressurize the tank. The opening of the tank is designed toaccept ordinary supply nozzles found at gas-stations. The pressure gauge fits into anadapter which contains a check valve that is designed to prevent fuel from escaping ifthe gauge is broken off. The filler cap assembly is designed with a slot at the end ofthe threads to permit tank pressure to be released before the cap is completelyunscrewed and a pressure relief valve that is set to release at a pressure of 35 psi.The hand pump is used to pressurize the system. The system is pressurized to aminimum of 10 psi for operation. The gasoline shutoff valve is a fast-flow ball checkthat shuts off the flow of the fuel if there is a sudden surge of fuel flow from the hosebeing cut, ruptured, or punctured.

The gasoline hose is a ¼-inch 2-braid hose designed specifically for gasoline. Theoxygen hose is 5/16-inch 1-braid type “S”, grade “T” designed to be resistant toabrasion, fire, and oil.

Torches are hand-held or machine-mounted and consist of hose connectors, a cuttinglever, a high pressure oxygen valve, a gasoline valve, a mixer, the tip nut, the cuttingtip, and the heating tip. The hose connectors are threaded brass tubes whichconnect the hoses to the base of the torch. The oxygen connector has a right handthread and the gasoline connector has a left hand thread. The cutting lever operatesthe high pressure oxygen valve which permits the oxygen to enter the work head.The gasoline valve runs the entire length of the torch and controls the gasoline flow atthe torch head. The mixer which is located in the torch head receives the pre-heatoxygen and the gasoline and combines them into a fuel mixture which is then fed into

SECTION 2: PROCESS DESCRIPTIONthe tip assembly. The cutting tip is a 2-piece assembly where the liquid fuel isvaporized, directed down to the base of the core, and re-directed out of the tipthrough the flutes of the core.

SECTION 3: PROCESS DIAGRAMS

SECTION 4: CONTAMINANTS AND MEDIASmoke and fume are generated during thermal cutting with the oxy-gasoline torch.Consideration needs to be given to the contaminants of the metal being cut, anycontaminants of coatings on the metal, and contamination in the area where the torchis being used for D&D activities. An air sampling plan will need to be developed, asappropriate for the site where the torch is used.

SECTION 5: ASSOCIATED SAFETY HAZARDSProbability of Occurrence of Hazard:

1 Hazard may be present but not expected over background level2 Some level of hazard above background level known to be present3 High hazard potential4 Potential for imminent danger to life and health

A. ELECTRICAL (LOCKOUT/TAGOUT) RISK RATING: N/ANot part of this technology.B. FIRE AND EXPLOSION RISK RATING: 4Heat, sparks, and flame present during thermal cutting has the potential to cause fireor explosion. When fire hazards present in the area cannot be moved, guards mustbe set up to contain heat, sparks, and slag.Oxygen itself is not flammable but it supports the burning process. Pure oxygen willdrastically increase the speed and force with which burning takes place.By definition, gasoline is considered a flammable liquid. Flammable liquids presenthazards to the worker and the environment where they are used. Appropriateprecautions need to be taken for storage, handling, and use.C. CONFINED SPACE ENTRY RISK RATING: 1-4Not part of this technology unless the specific location where the torch is being usedis a confined space. Thermal cutting operations can present additional hazards in aconfined space. Confined space entry and rescue procedures must be followed andadditional consideration given to the limited work space, hazardous atmosphere,slipping hazards, flammability, combustibility, and toxic fumes in relation to their abilityto be caused by the thermal cutting process itself.

SECTION 5: ASSOCIATED SAFETY HAZARDS (CONTINUED)D. MECHANICAL HAZARDS RISK RATING: 1Assembling the cylinders and the cutting torch poses pinch points.E. PRESSURE HAZARDS RISK RATING: 4The compressed gas cylinder presents hazards which are discussed under "K" of thissection.F. TRIPPING AND FALLING RISK RATING: 2Hoses present potential hazards.G. LADDERS AND PLATFORM RISK RATING: 2Not part of this technology but may be required for D&D activities. All regulations forworking from ladders and platforms, including the OSHA scaffolding standard must befollowed.H. MOVING VEHICLE RISK RATING: 2Not part of this technology but may be required for D&D activities. All precautionsand safety requirements for large pieces of equipment will need to be followed. Forexample, all moving vehicles should have working back-up alarms, warning lights,etc.I. BURIED UTILITIES, DRUMS, AND TANKS RISK RATING: N/ANot part of this technology.J. PROTRUDING OBJECTS RISK RATING: N/ANot part of this technology.K. GAS CYLINDERS RISK RATING: 4The compressed gas cylinder of oxygen accounts for one of the hazards associatedwith the oxy-gasoline torch. If the compressed gas cylinders are damaged, gas canescape with great force and the cylinder itself can explode causing injury to workersand possibly damaging property. One example of this type of hazard is called“rocketing”. The cylinder acts as a “rocket” if damaged or ruptured. The “rocket”(cylinder) can break through concrete walls or travel through open spaces.L. TRENCHING AND EXCAVATIONS RISK RATING: N/ANot part of this technology.M. OVERHEAD LIFTS RISK RATING: 2Not part of this technology but may be required during D&D activities. All applicablestandards and precautions must be followed for the type of equipment used. At aminimum, anyone in the work area should be wearing a hard hat.

SECTION 5: ASSOCIATED SAFETY HAZARDS (CONTINUED)N. OVERHEAD HAZARDS RISK RATING: 2May be part of this technology if the piece being cut is overhead. At a minimum,anyone working in the area should be wearing a hard hat. It needs to be assured thatall workers in the area are aware of the overhead work being done and avoid the areawhen possible.

SECTION 6: ASSOCIATED HEALTH HAZARDSA. INHALATION HAZARD RISK RATING: 3Fumes and gases produced by the thermal cutting process vary widely and arerelative to the metal being worked, coatings on the metal, and contaminants inherentin the environment where the metal is located. Gasoline vapors also have thepotential to present an inhalation hazard, especially when filling the tank, and must betaken into consideration when developing an air sampling plan.B. SKIN ABSORPTION RISK RATING: 2Gasoline is a skin hazard. It can irritate the skin, cause rashes, and defatting (severedrying) of the skin. Other skin hazards would be dependent on the contaminants atthe site and would be identified by the site characterization.C. HEAT STRESS RISK RATING: 4Ambient conditions, work rates, and PPE levels must be considered. The worker maybe subjected to an increase in heat stress due to the heat generated during thermalcutting operations. The sparking, flame, slag, and hot metal will all add to the heatload.D. NOISE RISK RATING: 2The technology presents a potential noise hazard.E. NON-IONIZING RADIATION RISK RATING: 1-4The ultraviolet light produced by the thermal cutting process can damage the eyes.This can be in the form of a “flash” burn or after long term exposure, cataracts.Proper protection for eyes when performing cutting operations using the oxy-gasolinetorch is the welding helmet with the correct filter in place. The filter lenses and platesmust meet the test for transmission of radiant energy as prescribed in ANSI Z87.1,Practice for Occupational and Educational Eye and Face Protection. Filter darknessneeds to be chosen in compliance with OSHA 29 CFR Subpart Q Welding, Cutting,Brazing. Other workers in the area must wear safety glasses with an appropriatedarkness rating. It is also recommended that dark clothing be worn to reducereflection under the welding helmet.F. IONIZING RADIATION RISK RATING: 1-4Not part of this technology, but may be associated with the area where D&D activitiesare taking place.

SECTION 6: ASSOCIATED HEALTH HAZARDSG. COLD STRESS RISK RATING: 1Technology does not produce a hazard, but ambient conditions need to beconsidered.

SECTION 6: ASSOCIATED HEALTH HAZARDS (CONTINUED)H. ERGONOMIC HAZARDS RISK RATING: 3During cutting operations, many ergonomic stressors can be placed on the body fromworking in awkward and static postures. There is also concern for the manual forceand repetitive motions that may be required. In order to make a cut, workers mayhave to get into tight places by twisting themselves into place or by propping theirbodies into awkward positions. Stresses occur from holding the head and arms inunnatural, fixed positions for long amounts of time. This often results in stiffness andsoreness in the body. Overhead work can result in a condition know as shouldertendonitis (inflammation of the tendons of the shoulder) and there is concern for thestress placed on the back from bending to cut pieces located on ground level.I. OTHER RISK RATING: N/ANone noted at this time.

SECTION 7: PHASE ANALYSISA. CONSTRUCTION/START-UPThe set-up/start-up phase presents several hazards including pinch points, struck byhazards slips/trips/falls, muscular/back injury, and exposure to compressed gas andgasoline.B. OPERATIONThe operational phase presents several hazards including exposure to contaminant,muscular/back injury, pinch points, laceration hazards, slips/trips/falls, pinch points,struck by hazards, exposure to noise, eye hazards (ultraviolet and infrared light), burnhazards, fire/explosion hazards, heat stress, and exposure to contaminants.C. MAINTENANCEThe maintenance phase presents several hazards including pinch points,slips/trips/falls, muscular/back injury, and exposure to contaminants.

SECTION 7: PHASE ANALYSIS (CONTINUED)D. DECOMMISSIONINGThe decommissioning phase presents several hazards, including exposure to thecontaminant, pinch points, slips/trips/falls, and muscular/back injury.

SECTION 8: HEALTH AND SAFETY PLAN REQUIRED ELEMENTSA. AIR MONITORINGFumes and gases produced by the thermal cutting process vary widely and arerelative to the metal being worked, coatings on the metal, and contaminants inherentin the environment where the metal is located. Iron oxide, nickel, cadmium, zinc,lead, oxides of nitrogen, and carbon dioxide are examples of the types of inhalationhazards that may be present during thermal cutting operations. A sampling plan willneed to take into consideration the vapors from the gasoline being used,contaminants specific for the site, and the pieces being cut. Noise monitoring willneed to be conducted.B. WORKER TRAININGTraining that may apply in this case may include but not be limited to: HAZWOPER(Hazardous Waste Operations and Emergency Response), HAZCOM (HazardCommunication), Respiratory Protection, PPE (Personal Protective Equipment)Training, Hearing Conservation, Fire Extinguisher, Heat Stress, Working withCompressed Gases, non-ionizing radiation training, Ergonomics (proper lifting,bending, stooping, kneeling), specific training for equipment operation, CPR/FirstAid/Emergency Response/Bloodborne Pathogens, Lockout/Tagout, Hand SignalCommunication, and Construction Safety (OSHA 500) and/or General Industry Safety(OSHA 501).C. EMERGENCY RESPONSEEmergency response planning for a site needs to assure adequate coverage forhazards described in the TSDS. Having at least one person per shift trained in CPRand first aid is recommended.D. MEDICAL SURVEILLANCEEvaluation of personnel’s general health with emphasis on the cardiovascular andrespiratory system and the back. In addition, medical surveillance as required byOSHA standards must be conducted. Initial and annual audiograms may be required.E. INFORMATIONAL PROGRAMWorkers must be trained in specific operation of equipment before use.

SECTION 9: COMMENTS AND SPECIAL CONSIDERATIONS

Only personnel who have been adequately trained in the operation of this technologyshould be permitted to operate and/or work with the equipment.

SECTION 7 - EMERGENCY RESPONSE/PREPAREDNESS

The use of the Oxy-gasoline Torch may be applicable to use in an emergencyresponse situation to access the area where the emergency has occurred or tocut up pieces that need to be moved. It would not be able to be used if there wasthe potential for an flammable or explosive atmosphere.

Emergency response/preparedness must be part of every hazardous waste sitesafety and health plan. In addition to credible site emergencies, site personnelmust plan for credible emergencies in connection with the oxy-gasoline torch.

All precautions used when responding to an emergency situation at the site willapply. Before entering an area where the oxy-gasoline torch is being used, theequipment needs to be completely shut down (de-energized: oxygen andgasoline sources turned off).

This technology does not appear to present conditions that could lead to out-of-the-ordinary emergency. Consideration does however, need to be given to thefire hazards associated with thermal cutting and the hazards associated with theuse of pressurized gases and flammable liquids.

SECTION 8 - REGULATORY/POLICY ISSUES

The site safety and health personnel where the Petrogen Oxy-gasoline Torch isbeing used need to be concerned with safety and health regulations applicable tothe issues discussed above. Regulations that apply may be divided into fourcategories. Core requirements are those regulations that would apply to anyhazardous waste work site, regardless of the type of job. Technology specificrequirements are those regulations that apply due to the specific technologybeing used. Special requirements are standards and policies that are specific tothe technology itself and are required by reference in a regulation. Bestmanagement practices are not required but are recommended by organizationssuch as the American National Standards Institute (ANSI), NIOSH, Departmentof Energy (DOE), National Fire Protection Association (NFPA), etc. Theseregulations/standards may include but not be limited to the following:

Core Requirements:

t OSHA 29 CFR 1926.25 Housekeeping

t OSHA 29 CFR 1910.141 Sanitation (1910.141(a)(3) covershousekeeping)

t OSHA 29 CFR 1926 Subpart Z Toxic and Hazardous Substances

t OSHA 29 CFR 1910 Subpart Z Toxic and Hazardous Substances

t OSHA 29 CFR 1926.59 Hazard Communication

t OSHA 29 CFR 1910.1200 Hazard Communication

t OSHA 29 CFR 1926.65 Hazardous Waste Operations and EmergencyResponse

t OSHA 29 CFR 1910.120 Hazardous Waste Operations and EmergencyResponse

t Occupational Safety and Health Act 1970(5)(a)(1) General Duty Clause

Technology Specific Requirements:

t OSHA 29 CFR 1910 Subpart Q Welding, Cutting and Brazing

t OSHA 29 CFR 1926 Subpart J Welding and Cutting

t OSHA 29 CFR 1910.147 The Control of Hazardous Energy(Lockout/Tagout)

t 29 CFR 1910.57 Ventilation

t OSHA 29 CFR 1910.94 Ventilation

t OSHA 29 CFR 1926.150 Fire Protection

t OSHA 29 CFR 1910.157 Portable Fire Extinguishers

t OSHA 29 CFR 1910.101 Compressed Gases (general requirements)

t OSHA 29 CFR 1926.102.152 Flammable and Combustible Liquids

t OSHA 29 CFR 1910.106 Flammable and Combustible Liquids

t OSHA 29 CFR 1926.103 Respiratory Protection

t OSHA 29 1910.134 Respiratory Protection

t OSHA 29 CFR 1926.52 Occupational Noise Exposure

t OSHA 29 CFR 1910.95 Occupational Noise Exposure

t OSHA 29 CFR 1926.102 Eye and Face Protection

t OSHA 29 CFR 1910.133 Eye and Face Protection

t OSHA 29 CFR 1926.28 Personal Protective Equipment

t OSHA 29 CFR 1910.132 General Requirements (Personal ProtectiveEquipment)

t OSHA 29 CFR 1926.23 First Aid and Medical Attention

t OSHA 29 CFR 1910.151 Medical Services and First Aid

t OSHA 29 CFR 1910.1000 Toxic and Hazardous Substances

Special Requirements:

t ANSI Z49.1-1967 Safety in Welding and Cutting published by theAmerican Welding Society

t 49 CFR Parts 171-179 Subchapter C – Hazardous Materials Regulations

t ANSI Z48.1 Method for Marking Portable Compressed Gas Containers toIdentify the Material Contained

t ANSI B57.1-1965 Compressed Gas Cylinder Valve Outlet and InletConnections

t ANSI Z87.1-1968 Practice for Occupational Eye and Face Protection

t Compressed Gas Association Pamphlet G-1-1966

t Compressed Gas Association Pamphlet P-1-1965

Best Management Practices:

t ACGIH Threshold Limit Values for Chemical Substances and PhysicalAgents and Biological Exposure Indices

t NIOSH Revised Lifting Equation, 1994

In addition to the above regulations and policies, it is imperative that all workershave appropriate and adequate training for the task and associated safety andhealth hazards. Training that would be required may be divided into fourcategories. Core training is that which is required for anyone entering ahazardous waste site to perform work, regardless of the type of job. Technologyspecific training is that training which is specific to the technology and required bysafety and health standards. Special training is that which is specific to the

technology to assure the worker is adequately trained for the task, but is notnecessarily required by safety and health standards. Best managementpractices are trainings that while not mandated by health and safety standards,provide information and knowledge to the worker that will allow the worker toperform his/her job safely. Training to be applied for the Petrogen Oxy-gasolineTorch may include but not be limited to:

Core Training Requirements:

t HAZWOPER

t HAZCOM

Technology Specific Training:

t Hearing Conservation

t Respiratory Protection

t Personal Protective Equipment

t Lockout/Tagout

t Fire Extinguisher

Special Training:

t Job specific training for equipment operation

Best Management Practice Training:

t Ergonomics (proper lifting, bending, stooping, kneeling)

t Heat stress (learning to recognize signs and symptoms)

t Working with Compressed Gases

t Non-ionizing radiation

t Working with Flammable Liquids

t CPR/First Aid/Emergency Response/Blood-borne Pathogens

t Hand Signal Communication

t Construction Safety (OSHA 500) and or General Industry Safety (OSHA501)

SECTION 9 -OPERATIONAL CONSIDERATIONS & RECOMMENDATIONS

Recommendations made here for improved worker safety and health take intoconsideration the operation of the Oxy-gasoline Torch. Specificrecommendations include:

t Workers must be aware of the tripping hazards associated with hoses thatare necessary to operate the equipment. Keeping these as orderly aspossible in compliance with good housekeeping regulations will help avoidinjury due to tripping.

t The operators need to have training in ergonomics to assure propertechniques in lifting, bending, stooping, twisting, etc. during equipmentsetup, operation, maintenance, and decontamination.

During cutting operations, many ergonomic stressors were placed on thebody from working in awkward and static postures. There is also concernfor the manual force and repetitive motions that may be required. In orderto make a cut, the workers had to get into tight places by twistingthemselves into place or by propping their bodies into awkward positions.Stresses occur from holding the head and arms in unnatural, fixedpositions for long amounts of time. This often results in stiffness andsoreness in the body. Overhead work can result in a condition know asshoulder tendonitis (inflammation of the tendons of the shoulder) andthere is concern for the stress placed on the back from bending to cutpieces located on ground level.

It is recommended that pre-planning to place the operator in the bestposition, for ergonomics and safety be done before operations begin andperiodically as the job progresses. Workers should not place themselvesin positions that cause the body discomfort but since many times theseawkward postures are unavoidable, workers should, at the first sign ofsoreness, stop and stretch.

t Workers may need to be included in a hearing conservation programbased on the noise levels specific to the location where the torch is beingused. Differences in noise exposure will be based on the location of theworker in relation to the cutting operation and the amount of time theworker spends there. A sampling plan will need to be developed toaddress the site specific conditions where the thermal cutting operationtakes place. A sampling plan should also take into consideration the workenvironment since the noise levels may increase or decrease based on

the construction of the enclosure where the cutting operation is takingplace.

t Air sampling for welding fume, as total particulate, nitrogen dioxide,carbon monoxide, carbon dioxide, and ozone did not show any exposuresabove the OSHA PEL or the ACGIH TLV. Smoke and fumes however,were visible during the operation of the oxy-gasoline torch. The timespent in the work area, the distance from the actual cutting operation, andventilation in the work area will affect an individual worker’s exposurelevel. A complete sampling plan will need to be developed to account forthe site specific conditions including contaminants specific to the D&Dproject. The metal being cut with the torch needs to be taken intoconsideration and contaminants specific to the metal and any coatings onthe metal need to be monitored.

t Gasoline is the fuel used with oxygen for operation of the torch. Thetorch will work with any grade of gasoline but it will not operate onkerosene, diesel fuel, or gasohol. It is recommended that leaded gasolinenot be used in the torch because of the additional hazards that may becreated by the lead.

The tank has safety features to mitigate the hazards previously associatedwith the use of oxy-gasoline torches. These safety features include:

• The gasoline is liquid all the way to the tip where it is vaporized.• Any surge in the fuel delivery is stopped by the activation of the

gasoline flow check valve.• If the tank is caught in a fire, the gasoline inside will vaporize and exit

through the relief valve. The gasoline insidewill not explode.

Proper precautions do need to be followedwhen handling, using, and storing gasoline.These may include by not be limited to:

• Never use gasoline for cleaning floors,tools, clothes, or hands.

• Always store gasoline in an approvedclosed container.

• Do not pour gasoline from one container toanother to avoid the generation of staticelectricity, if this must be done be sure tomaintain metal to metal contact.

• Clean up gasoline spills immediately to prevent the accumulation ofvapors.

Figure 3. Gasoline tank usedwith oxy-gasoline torch.

• If gasoline is spilled on oneself, remove any saturated clothesimmediately and keep the clothing away from sources of ignition andwash the affected area of skin with soap and water.

• If gasoline gets in the eyes, flush them with water and get medicalattention.

t Heat stress is a hazard for all workers. When the worker must use certaintypes of PPE the heat stress on the worker isincreased. This is a concern because duringthermal cutting operations flame-resistantclothing must be worn, sometimes in addition toPPE necessary to protect against othercontaminants in the area where the cuttingoperation is being conducted. In addition, theremay be an increase in heat stress due to theheat generated from sparks, flame, slag, and hotmetal. A heat stress program taking all of thesefactors into consideration needs to be developedfor the site where the oxy-gasoline torch isbeing used for thermal cutting operations. It isrecommended that personal cooling devices beused as appropriate to help alleviate the heat

stress hazard for the worker.

t The thermal cutting process creates sparks, spatter, and ultraviolet light.These have the potential to be eye and skin hazards. They may causeeye or skin burns. Protective clothing made of flame-retardant materialshould be worn to minimize skin burns. It is also recommended that allparts of the body be covered to prevent flash burn from ultraviolet andinfrared rays. Clothing that can melt or can cause severe burn due tosparks that may lodge in rolled-up sleeves, pockets on clothing, or pantcuffs should never be worn. Additional recommendations to prevent skinburns include:1. always point the cutting tip away from yourself and other people in thearea when lighting the torch, 2. never light the torch with anything otherthan a striker designed for that purpose, 3. pre-plan cuts to directsparking away from the worker when possible, 4. assure all workers in thearea are aware of hot metal from cuts, and 5. use gloves for hot work tohandle hot metal pieces.

The sparks and spatter not only present a burn hazard for the eye but aphysical hazard as well. The welding helmet will protect the eyes fromsparks and spatter that strike directly against it but it is not intended toprotect against those that ricochet under the helmet. It is recommendedthat safety glasses with side shields, goggles, or other appropriate eye

Figure 4. Slag and hotmetal add to the heatstress on the worker.

protection be worn under the welding helmet to protect against theseimpact hazards.

The ultraviolet light produced by the thermal cutting process can damagethe eyes. This can be in the form of a “flash”burn or after long term exposure, cataracts.Proper protection for eyes when performingcutting operations using the oxy-gasoline torchis the welding helmet with the correct filter inplace. The filter lenses and plates must meetthe test for transmission of radiant energy asprescribed in ANSI Z87.1, Practice forOccupational and Educational Eye and FaceProtection. Filter darkness needs to bechosen in compliance with OSHA 29 CFRSubpart Q Welding, Cutting, Brazing. Other

workers in the area must wear safety glasseswith an appropriate darkness rating. It is alsorecommended that dark clothing be worn toreduce reflection under the welding helmet.

t There may be times when slag will have to chipped from the piece thatwas cut. This should only be done by using a slag-chipping hammer or achisel. An ordinary carpenter’s hammer should never be used becausethe head of the carpenter’s hammer can splinter and split. Safety glassesmust always be worn when chipping slag. Hearing protection may also berequired depending on the type of chipping hammer or chisel that is used.

t If cement or stone surfaces are heated by the torch, the moisture withinthese materials could cause them to explode when they reach a certaintemperature. The torch should never be purposefully aimed at cement orstone surfaces. Realizing this is not always possible because of a cut thatneeds to be made, safety glasses with side shields, goggles, or otherappropriate eye protection must be worn under the welding helmet toprotect against these impact hazards.

t The edges of the cut metal pieces may be sharp. These presentcut/puncture/laceration hazards to the worker. In addition, contaminantson the metal piece could become “contamination through injection”because of the wound. Sharp metal pieces should never be handledwithout puncture resistant gloves being used.

t Thermal cutting operations present many opportunities for fire andexplosion hazards. It needs to be assured that there are no flammables inor near the area where the cutting operation is to take place. Specialprecautions need to be taken before cutting drums, tanks, or closed

Figure 5. Sparks createdduring cutting of an I-beam.

containers to determine if they previously held flammable materials.Before the cutting operation begins all combustible materials should bemoved, if possible. If it is not possible to move the combustibles, guardsneed to be set up to contain heat, sparks, and flame. A fire watch must bepresent and appropriate fire protection equipment, such as fireextinguishers must be available. It must also be assured that workers areproperly trained to use the fire protection equipment that is madeavailable.

t Adequate breathing air must be provided during the thermal cuttingoperation. To keep fumes, vapors, and other toxic by-products at safelevels, the work area must be properly ventilated. Natural ventilation maybe used if the necessary precautions are taken to keep the worker’sbreathing zone away from the fume plume and air sampling showsconcentrations of contaminants are below the allowable levels. Whennatural ventilation is not adequate, mechanical ventilation will benecessary. This may include local exhaust, local forced, and general areaair movement systems. Examples of local exhaust systems to beconsidered are a suction device placed on the cutting torch itself orseparate hoods placed near the cutting operation. Additional factors thatneed to be taken into consideration to determine ventilation requirementsinclude: 1. dimensions and layout of the area of operation, 2. the numberof cutting operations taking place in the area, 3. the rate of cutting, and 4.the tendency of air currents to dissipate or concentrate fumes in certainareas of the work site.

The workers must take precautions to avoid placing themselves insituations where they are breathing the fume plume directly. Methods ofdoing this include positioning the head, the work, or by ventilation thatdirects the plume away from the worker’s face. Tests have shown thatventilation directed across the face of the worker is more effective than airdirected from behind the worker.

t One of the hazards associated with oxy-gasoline thermal cutting is the useof a compressed gas cylinder. If the compressed gas cylinder isdamaged, gas can escape with great force or the cylinder itself canexplode, injuring workers. The worker should look for signs that indicatethere could be danger associated with the compressed gas cylinder.These danger signs include: leaking, corrosion, cracks or burn marks,contaminated valves, worn or corroded hoses, and broken gauges orregulators.

Recommendations to mitigate dangers associated with the handling ofcompressed gas cylinders include but are not limited to:

• Accept only cylinders approved by the Department of Transportation(DOT).

• Do not remove or change marks and numbers stamped on thecylinders.

• Cylinders may be rolled on the bottom edge, but never dragged.• When cylinders are transported on a hand or motorized truck they

must be secured to keep them from falling.• Keep cylinders clean and protect them from cuts or abrasions.• Do not use an electro-magnet or slings to hoist cylinders.• Do not drop cylinders or allow them to strike each other violently.• Do not use cylinders for rollers or supports.• Do not tamper with safety devices on valves or cylinders.• Clearly identify empty cylinders.• Assure all cylinders not in use have the valve protection caps in place.• Handle all cylinders as if they were full.

Recommendations for storing cylinders include but are not limited to:

• Store cylinders in an upright position in a safe, dry, well-ventilatedarea.

• Do not store flammable substances, i.e. oil and volatile substances, inthe same area as cylinders.

• Do not store cylinders near elevators, gangways, or stairwells wherethey could be knocked down.

• Oxygen cylinders should not be stored within 20 feet of highlycombustible materials or cylinders containing flammable gases. If theyare closer than 20 feet, cylinders should be separated by a fire-resistive partition at least 5 feet high with a fire-resistance rating of atleast 30 minutes.

• Acetylene and liquefied fuel gas should be stored with the valve endup.

• Store liquefied fuel gas in accordance with NFPA limits for capacity.• Store cylinders on a level fire-proof floor.• To help prevent rusting store off of the ground and protect from the

weather, if the cylinders are stored outside.• Do not store cylinders near sources of heat.• Use oldest cylinders first.

Recommendations for using cylinders include but are not limited to:

• Use cylinders in upright position and secure so they cannot fall or beknocked over.

• Keep metal cap in place to protect the valve when the cylinder is notconnected for use.

• Make sure threads on regulator or union correspond to those on thecylinder valve outlet – do not force connections that do not fit.

• Do not use cylinder of compressed gas without a pressure-reducingregulator attached to the cylinder valve.

• Before making a connection to a cylinder valve outlet, “crack” the valveto clear particles of dust and dirt.

• Use regulators and pressure gauges only with the gases for which theyare designed.

• Take leaking fuel gas cylinders out of use immediately.• Do not permit sparks, molten metal, electric currents, excessive heat,

or flames to come into contact with the cylinder or attachments.• Never use oil or grease as a lubricant on valves or attachments of

oxygen cylinders.• Do not handle oxygen cylinders with oil or grease on your clothing.• Never use oxygen as a replacement for compressed air.• Never take cylinders into tanks or unventilated rooms.• Before removing a regulator, close the cylinder valve and release the

gas from the regulator.• Close the cylinder valves when the work is finished – the valve should

be closed between cuttings.

The environment where the D&D activities are taking place has the potential toaffect both the contaminant and noise levels generated. Therefore, the need foran air sampling and noise monitoring program needs to be assessed on a site-by-site job-by-job basis.

APPENDIX AREFERENCES

Clayton & Clayton, Editors, Patty’s Industrial Hygiene and Toxicology, Volume 1,Part A, Fourth Edition

DOE Lessons Learned, Identifier 1997-RL-FDH-0001,http://www.hanford.gov/lessons/site11/1197/970001b.htm

DOE Lessons Learned, Identifier 1995-RL-WHC-040,http://www.hanford.gov/lessons/site11/1195/95e040.txt

DOE Lessons Learned, Identifier 1995-RL-WHC-0037,http://www.hanford.gov/lessons/site11/1195/95i037.txt

Keller’s Official OSHA Safety Handbook, J.J. Keller & Associates, Nihau,Wisconsin, 1996

National Safety Council, Accident Prevention Manual for Business and Industry,11th Edition, 1997

Occupational Safety and Health Standards for General Industry, 29 CFR Part1910, Occupational Safety and Health Administration United States Departmentof Labor

Occupational Safety and Health Standards for the Construction Industry, 29 CFRPart 1926, Occupational Safety and Health Administration United StatesDepartment of Labor

Salvendy, Editor, Handbook of Human Factors and Ergonomics, 1997

Threshold Limit Values (TLV’s) for Chemical Substances and Physical Agentsand Biological Exposure Indices (BEI’s), American Conference of GovernmentalIndustrial Hygienists, 1995-1996

UMASS/Lowell, Department of Work Environment, ”On the Beam” ConstructionOccupational Health Project, A Look at the Hazards and Controls for Welding,Vol. 1, No. 3, Summer 1998

U.S. Department of Health and Human Services, Manual for the Revised NIOSHLifting Equation, January 1994

Petrogen International, Ltd., Oxy-Gasoline Safety Torch, Reference Manual

APPENDIX BIH SAMPLING DATA

Framatome Technologies Oxy-gasoline TorchAir Sampling

Date Sample Number Analyte * Results

8/25/98 082598-FIU-018 Blank < 0.05 mg/m3

8/25/98 082598-FIU-020 Welding fume, totalparticulate

0.101 mg/m3

8/25/98 082598-FIU-019 Welding fume, totalparticulate

1.136 mg/m3

8/25/98 082598-FIU-040 Nitrogen Dioxide < 1.30 ppm


8/25/98 082598-FIU-042 Carbon Dioxide 395.78 ppm

8/25/98 082598-FIU-043 Carbon Dioxide 395.75 ppm

8/25/98 082598-FIU-044 Carbon Monoxide < 6.52 ppm


8/25/98 082598-FIU-046 Ozone < 0.05 ppm

8/25/98 082598-FIU-047 Ozone < 0.05 ppm


8/26/98 082698-FIU-049 Carbon Dioxide 500 ppm


* The OSHA PEL for welding fume, total particulate is 15 mg/m3 and the ACGIHTLV is 5 mg/m3, for nitrogen dioxide the OSHA PEL is 5 ppm (as a ceiling level)and the ACGIH TLV is 3 ppm, for carbon dioxide the OSHA PEL and the ACGIHTLV is 5000 ppm, for carbon monoxide the OSHA PEL is 50 ppm and the ACGIHTLV is 25 ppm, and for ozone the OSHA PEL is 0.1 ppm and the ACGIH TLV is0.1-0.05 ppm, depending on the work load. An air monitoring plan will need toaddress contaminants specific to the site where the oxy-gasoline torch is beingused.

NOISE SAMPLING

NOISE SAMPLING

The percentage of time spent at each decibel level can be obtained from thegraph. As shown, 91.649% of the time the noise exposure was less than 85dBA, which means 8.351% of the time, was spent at sound levels above 85 dBA.OSHA requires that a hearing conservation program be initiated if the 8-hourTWA is 85 dBA.

NOISE SAMPLING

NOISE SAMPLING

The percentage of time spent at each decibel level can be obtained from the graph. Asshown, 96.50% of the time the noise exposure was less than 85 dBA, which means 3.50%of the time, was spent at sound levels above 85 dBA. OSHA requires that a hearingconservation program be initiated if the 8-hour TWA is 85 dBA.

APPENDIX CACRONYM SHEET

ACGIH - American Conference of Governmental Industrial HygienistsAIHA - American Industrial Hygiene AssociationANSI - American National Standards InstituteASME - American Society of Mechanical EngineersASTM - American Standards for Testing MaterialsCFR - Code of Federal RegulationsD&D - decontamination and decommissioningDOE - Department of EnergyDOT - Department of TransportationFIU - Florida International UniversityHAZCOM - Hazard CommunicationHAZWOPER - Hazardous Waste OperationsMSDS - Material Safety Data SheetNIOSH - National Institute of Occupational Safety and HealthNFPA - National Fire Protection AssociationOSHA - Occupational Safety and Health AdministrationPEL - permissible exposure limitPPE - personal protective equipmentppm - parts per millionpsi - pressure per square inchpsig - pounds per square inch gaugePVC - polyvinyl chlorideSOP’s - standard operating proceduresTLV - threshold limit valueTSDS - Technology Safety Data SheetTWA - Time Weighted Averageµg - microgramsUL - Underwriter’s Laboratory

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