Compressor_Maintenance_IH_Survey_240A1.pdf

DEPARTMENT OF THE AIR FORCE

75TH AEROSPACE MEDICINE SQUADRON (AFMC)

HILL AIR FORCE BASE, UTAH

31 July 2012

MEMORANDUM FOR 530 CMMXS/CL

530 CMMXS/MXDPCCC

FROM: 75 AMDS/SGPB

SUBJECT: Industrial Hygiene Assessment, Gas Turbine Engine Test Cell, Building 240, PEG: 240A1

1. Attached is the 75 AMDS Bioenvironmental Engineering (BE) Industrial Hygiene

Assessment for your shop. This assessment was done on 5 July 2012 by SrA Chris Heil. An opening conference was conducted with Ronnie Dale. AFGE was contacted 2 July 2012. This assessment was accomplished in accordance with AFI 48-145, Occupational and Environmental

Health Program.

2. Your shop is not in compliance with Air Force and Federal regulations.

Engineering and administrative controls of noise hazards must be considered. BE must have documentation that all processes involving hazardous noise producing equipment cannot be completed in a way that does not create a hazard to personnel. Of specific concern is the hazardous noise levels outside the test cell. It is not feasible to engineer out the noise when the worker is in the cell with a unit running. Work with BE and your engineering function to review engineering and/or administrative controls for noise hazards or to document that alternative methods of controls are not practical.

3. Your workplace has been identified as a Category 2 shop which is defined as a medium risk workplace. Your shop will be surveyed every two years. In accordance with AFI 91-202, The

US Air Force Mishap Prevention Program, 5 August 2011, supervisors must brief all personnel of the findings and recommendations in this report and post it in the work area for a minimum of ten days. This report must be kept on file for two years. Make this report available to new personnel as a part of their initial workplace safety briefing. When you have changes in personnel, it is your responsibility to inform Kathleen Biegenwald by fax at 777-1050 or e-mail at Kathleen.Biegenwald@hill.af.mil.

4. Thank you for your help in conducting this assessment. Please contact SrA Heil at

777-4551 or e-mail at christopher.heil@hill.af.mil if your work conditions change or if you have any questions regarding occupational health matters. OSHA Standard 29 CFR 1910.1020, Access to Employee Exposure and Medical Records, requires that employees receive an annual briefing on the availability of medical and exposure records. A signed copy of this report and all mailto:Kathleen.Turner@hill.af.mil mailto:christopher.heil@hill.af.mil other applicable industrial hygiene data are maintained in our office, Building 249, and is available for your review. Medical records for civilians are located in the Occupational Health

Clinic, Building 249. Military medical records are located in the main clinic, Building 570.

7/31/2012

X

CARY FISHER, GS-13, DAF

Industrial Hygiene Supervisor

Attachments:

1. Response to Findings and Recommendations

2. Industrial Hygiene Assessment

3. Health Hazard Controls and PPE Certification

4. Hazardous Noise Assessment Data

5. Fetal Protection Information cc:

75 ABW/SEG - Ron James

75 AMDS/SGPM - Jolene Garner

309 CMXG/QPDB – Victor Rodriguez

309 CMXG/CL - Richard Buhl

OO-ALC/SE – Kerry Miller/Tim Helms

309 CMXG/ENV- Guy Whalen

309 CMXG/EN – Allan Cooley

309 CMXG/OB – Shayla Gilbert

5 July 2012

Attachment 1

RESPONSE TO FINDINGS AND RECOMMENDATIONS

Recommended actions for 530 CMMXS/MXDPCCC, Gas Turbine Engine Test Cell, PEG:

240A1

RETURN THIS SHEET TO 75 AMDS/SGPB NLT 31 August 2012

FINDINGS AND RECOMMENDATIONS ACTION TAKEN

Engineering and administrative controls of noise hazards must be considered. BE must have documentation that all processes involving hazardous noise producing equipment cannot be completed in a way that does not create a hazard to personnel. Of specific concern is the hazardous noise levels outside the test cell.

It is not feasible to engineer out the noise when the worker is in the cell with a unit running. Work with BE and your engineering function to review engineering and/or administrative controls for noise hazards or to document that alternative methods of controls are not practical.

5 July 2012

Attachment 2

Industrial Hygiene Assessment

1. Use of Engineering Controls: OSHA requires hazards be abated with the use of engineering and administrative controls where feasible. Personal protective equipment, such as respirators, is considered an interim solution. Noise dosimetry has shown that your engineering and administrative controls are not controlling worker exposures below allowable exposure levels outside of the test cells. Recommend your engineering function review changes in processes, material substitution, additional engineering, or administrative controls. Your organization needs to show what controls have been considered and the future actions that will be taken to reduce these exposures.

2. Personal Protective Equipment (PPE)(AFI 91-203): Attachment 3 lists the tasks that were evaluated for health hazards, PPE use and effectiveness, and the limitations of existing PPE during our survey. This serves as the PPE certification required by AFI 91-203. If there are changes to any of the activities discussed during this survey (including but not limited to changes in frequency, exposure time, application method, chemicals, or process redesign), the supervisor must notify our office so we can reevaluate the potential health risks and PPE requirements.

3. Occupational Safety and Health Administration (OSHA) Expanded Standard

Chemicals: There are no OSHA expanded standard chemicals used in this shop.

4. ESOHCAMP Tier 1 Checklists (AFI 90-803): In accordance with AFI 90-803, we provided you ESOHCAMP tier 1 checklists for occupational health items associated to your shop. These checklist need to be completed quarterly.

5. Noise (AFOSH Std 48-20):

a. The equipment listed in Attachment 4 produces hazardous noise and must have the appropriate label (AF Visual Aid 48-102 through 48-105). The equipment is labeled. The entrance to or the borders of a hazardous noise area must be labeled with AF Visual Aid

48-101, Caution – Hazardous Noise – May Cause Hearing Loss – Hearing Protection Required

When Equipment is in Operation. Hearing protection is required only when the source is producing noise. The hazardous noise areas were labeled.

b. Evaluation of worker exposure: The Air Force noise exposure limit is 85 dBA as an eight-hour, time-weighted average. We determined that your workers exceed the exposure limit. A summary of our monitoring is provided in Attachment 4. The requirement for annual hearing tests is based on measured worker exposure and periodic review of the information by

Occupational Medicine and Audiology.

c. Controls: Hearing loss is preventable. Engineering controls are the most preferred method in reducing exposure, but often the only practical way to control exposures is the use of hearing protection. When worn correctly, the hearing protection you are currently using (E.A.R Classic ear plugs and Peltor H10A Optime 105 ear muffs) is adequate to reduce noise exposure. If you change to a different brand of hearing protection not listed in Attachment 3, contact us to determine if it is adequate. New equipment must meet hazardous noise standards in AFOSH Std

48-20, Occupational Noise and Hearing Conservation Program.

d. Regulations: OSHA requires that supervisors and workers have access to the regulations governing the Hearing Conservation Program and hazardous noise exposure, 29 CFR 1910.95, Occupational Noise Exposure. The regulation is available on the internet at the US Government

Printing Office, http://www.gpo.gov/fdsys/search/home.action.

6. Emergency Eyewash: IAW AFI 91-203, Air Force Consolidated Occupational Safety

Instruction, the eyewash stations located throughout the test cell shop are readily accessible. The stations are tested weekly and inspected on a monthly basis. The stations are fully operational and adequate.

7. Hazard Communication (HAZCOM) Program (AFI 90-821/HAFBI 48-106): Your

HAZCOM Program is available in electronic format. We questioned three workers about hazard communication. Workers questioned knew how to access this information. Workers could explain the hazard of the material they were using. They could explain what PPE was required for the task they were doing. Supervisors have a workplace-specific lesson plan. Your lesson plan was reviewed. Based on the results of the review and worker answers to questions, your program is in compliance with BE and Public Health (PH) requirements. Contact BE if you need assistance with your program or training issues.

8. Thermal Injury: Shop personnel are potentially exposed to thermal (extreme heat or cold) injury when refueling the JP-8 support tank and when working in test cells. Personnel are periodically briefed on the hazards, prevention, symptoms, and signs of heat and cold stress related illnesses. Additionally, personnel are given opportunities to take breaks as needed to avoid thermal stress while performing assigned duties. For specific guidance on heat stress, refer to AFPAM 48-151, Thermal Injury. Wind chill temperatures and heat stress levels are posted on the Hill Air Force Base SharePoint site, https://cs.eis.afmc.af.mil/sites/Hill/default.aspx.

9. Reproductive Health: Attachment 5 lists chemicals used in this shop that may be hazardous to a developing fetus or affect the male or female reproductive system. Supervisors should ensure that pregnant women have their workplace reviewed by Public Health, 777-1170.

10. Work Practice Controls: No smoking, eating, or drinking is allowed in industrial work areas. Ensure your workers practice good personal hygiene by washing their hands with soap and water immediately after handling chemicals. This reduces the risk of workers accidentally ingesting toxic/hazardous substances. Personnel are maintaining good routine maintenance, sanitation, and housekeeping practices. These are essential to ensuring a safe and healthy environment.

11. Self-Help Projects: These projects need to be coordinated through the electronic 332 work request system so they can be reviewed by BE, Safety, Fire Department, and Environmental http://www.gpo.gov/fdsys/search/home.action https://cs.eis.afmc.af.mil/sites/Hill/default.aspx

Management prior to starting work. Some work areas have asbestos-containing materials like floor tile and lead-containing materials such as paint or ceramic tile. There are potential health hazards and environmental requirements that must be considered when these materials are disturbed.

12. Future Changes: If workload, operations, equipment, tasks, or chemicals used change significantly, we will need to reevaluate the health hazards in your workplace. Notify us of any changes as soon as possible so we may evaluate them.

Attachment 3

HEALTH HAZARD CONTROLS AND PPE CERTIFICATION

ACTIVITY HAZARDS

CONTROLS

PPE, Engineering, Admin

CONTROL LIMITATIONS

and PPE CHANGE OUT

FREQUENCY

Testing of

Overhauled

Engine parts

(Accessory Drive

Gear Box, Air

Turbine Starter, Aircraft Mounted

Accessory Drive

(AMAD), Central

Gear Box, Gas

Turbine Engine, and Jet Fuel

Starters)

Inhalation (vapors from potential jet engine fuel spills/ exhaust fumes)

General room ventilation and exhaust stacks.

N/A

Contact (thermal heat from handling hot engine parts, Mineral Oil)

Ironclad heat resistant gloves or Hercules Type II heat resistant gloves.

Gloves should protect against hot surfaces. Minimal chemical protection, may absorb chemicals. Replace when torn.

Personal Hygiene Do not eat in work areas, wash hands before eating

Noise (engine run-ups in test cells)

E.A.R. Classic plugs

NRR = 22 dB, not for noise levels above 107 dB.

Peltor H10A Optime 105 ear muffs

NRR = 22 dB, not for noise levels above 107 dB. Double protection required for noise levels above 107 dB.

Hearing Conservation

Program N/A

Use of

Lubricants on

Engine

Components

Contact (lubricating oil and lubricating grease)

Face shield

Will not protect from inhalation hazards or will it encapsulate or protect face from chemical immersion.

Nitrile Rubber Gloves

Minimal tear and heat resistance.

Replace when ripped or torn.

One time use only.

Breakthrough time is 8hrs. Must be >0.3 mm thick.

Butyl Rubber aprons

Provides no protection from caustic chemical vapors. Replace when torn.

Use of

Sealants/epoxy

When Testing

Turbines

Contact Primer

Torque Seal Dow

Corning Prime

Coat/Clear

Nitrile Rubber Gloves

Minimal tear and heat resistance.

Replace when ripped or torn.

One time use only.

Breakthrough time is 1hr. for acetone Must be >0.3 mm thick.

Personal Hygiene Wash hands before eating. Do not eat in work area.

HEALTH HAZARD CONTROLS AND PPE CERTIFICATION

ACTIVITY HAZARDS

CONTROLS

PPE, Engineering, Admin

CONTROL LIMITATIONS

and PPE CHANGE OUT

FREQUENCY

Solvent Cleaning of Engine

Parts/test Stations

Contact (isopropyl alcohol) Nitrile Rubber Gloves

Minimal tear and heat resistance.

Replace when ripped or torn.

One time use only.

Breakthrough time is 8hrs. Must be >0.3 mm thick.

General Shop

Cleaning

Contact (All

Purpose cleaner) Nitrile Rubber Gloves

Minimal tear and heat resistance.

Replace when ripped or torn.

One time use only.

Breakthrough time is 8hrs. Must be >0.3 mm thick.

Attachment 4

Noise Producing Equipment and Areas

EQUIPMENT

or AREA

Measured dBA

Distance from equipment hearing protection must be worn

(85 dBA Line)

Approved hearing protection

Jet fuel systems check*

Entire test cell

E.A.R. Classic ear plugs

(NRR=22 dB)

Peltor H10A Optime 105 ear muffs

(NRR=22 dB)

GTE air bleed check*

Chamber test

MOD valves

Outside Engine

Test Cell 121

87.9 3 ft

Operator position

Test Cell 107

85.9 3 ft

Operator Position

Test Cell 108

88.4 3 ft

* Requires ear plugs and ear muffs

(All noise PPE has been evaluated using a “NRR-7dBA” conservative calculation. The actual

NRR reported in this letter will not reflect manufacturer rating )

Noise Exposure Monitoring

Person Monitored Date Duties Average dBA

(8 hr)

Schneider, Kirk P. 2004/11/23 Employee worked in control room 116. Entered test cell to make adjustments during test run.

97.3

Giamberdini, Thomas P. 2004/11/23 Employee worked in control room 116. Entered test cell to make adjustments during test run.

103.6

Cresci, Lloyd G. 2004/11/23

Employee worked in control room 119. Worker entered test cell to make adjustments during test run.

106.1

Aspinwall, John W. 2004/11/23 Employee worked in control room 119.

Worked in control room during GTE test.

87.44

Attachment 5

Female Reproductive Hazards

HAZARDOUS

CONSTITUENT &

EXPOSURE ROUTES

ACTIVITY WHERE

CHEMICAL IS USED

POTENTIAL HAZARD

Acetone

Inhalation, Ingestion, Contact

Use of sealants/epoxy when testing turbines

- Not a known reproductive hazard, but may have adverse effects on female fertility and pregnancy.

- Earlier than normal menstrual period at levels slightly above the OEEL.

- Freely crosses the placenta.

2-Butoxyethanol

General Shop Cleaning - Does not appear to be selectively fetotoxic, embryotoxic, or teratogenic in animals at doses which are not toxic to the mother.

Carbon monoxide (CO)

Inhalation, Contact

(liquid)

Workers have potential exposure to carbon monoxide when entering test cells to make adjustments during test runs. The time spent making adjustments to engine components inside test cells can vary from a 20 to

30 minutes per engine. Workers usually test two engines per day.

- Known to have neurological effects on the fetus; doesn’t have a “no effect” level

- Chronic occupational exposures to low levels of CO would be of comparable risk to the fetus as smoking in the mother

- If a pregnant women smokes and ALSO is exposed to CO on the job; she may be at increased risk for having a child with neurological problems

Ethanol

Use of Sealants/epoxy When Testing

Turbines

- Ethanol ingestion by pregnant women is known to cause fetal alcohol syndrome

(low birth weight, low IQ, slow growth, facial abnormalities, nervous system defects, other malformations).

- Not clear if exposures which are solely occupational (below the OEEL) are sufficient to be a reproductive risk.

Ethylene glycol

Use of sealants/epoxy when testing turbines

- Mixed reproductive hazard results in animals.

- Teratogenic effects in animals were generally produced at very high levels.

- No human reproductive studies available, so the reproductive hazard in humans is unknown.

HAZARDOUS

CONSTITUENT &

EXPOSURE ROUTES

ACTIVITY WHERE

CHEMICAL IS USED

POTENTIAL HAZARD

Methyl ethyl ketone

Use of sealants/epoxy when testing turbines

- Not sufficient evidence to regard it as an occupational reproductive hazard, but should be considered a possible hazard until more is learned.

Xylene

Use of Sealants/epoxy When Testing

Turbines

- Not a teratogen in laboratory animals.

- High levels of exposure may be linked to birth defects and possibly menstrual disturbances.

- Occupational (low-level) exposure to xylene is unlikely to cause harm to human reproduction.

Male Reproductive Hazards

Hazardous Constituent

& Exposure Routes

Chemical Name/NSN/Activity

Chemical Used For Potential Hazard

2-Butoxyethanol

General Shop Cleaning -Testicular effects

Excessive heat Activity: Workers have potential exposure to excessive heat when entering test cells to make adjustments during test runs. The time spent making adjustments to engine components inside test cells can vary from a 20 to 30 minutes per engine. Workers usually test two engines per day.

-Heat can increase sperm abnormalities and infertility in the male

Ethanol

Use of Sealants/epoxy When Testing

Turbines

- Can affect male fertility and produce reduced birth weight in newborns through paternal exposure.

- Not clear if exposures which are solely occupational (below the OEEL) are sufficient to be a reproductive risk.