Boiler Manufacture Sampling Methods - Assignment Example

Boiler Manufacture Sampling Methods Abstract The content of this paper follows an evaluation of the boiler manufacturing process as provided. The process is analysed from the initialization of the boiler design to its completion with the working environment assessed for hazards. Identified hazards are discussed, and the means of handling the hazards are mentioned. In addition, the techniques used to determine the workers’ level of exposure have been covered in the paper. Introduction A boiler is a system where combustion of a fuel is used as a source of energy channelled to the water enclosed in a vessel to a point where it attains a present heat degree or vaporizes into steam. The steam of heated water is used to supply heat energy to other industrial processes, or for power generation. Designing boilers is based on several factors such as the fuel characteristics, output product, and application (Henry, 2009). The boiler characteristics are unique to its application and the configuration in size as well as configuration. The choice of materials used in the boiler manufacture process also follows the requirements of the product (Metcalf, 2008). a. Industrial Process Prior to the construction of the boiler, the engineers have to design the system. The boiler has to adhere to the specifications of the client; thus, the design phase is necessary where the engineers confer with the client. The purpose, process demand, environment, frequency of use, type of fuel, and other attributes of the boiler are addressed in the design phase (Bohle & Quinlan, 2000). Factoring the information, the boiler can then be developed by considering the available space, its fit into an industrial process and operation conditions. Fabrication of the boiler is the most involving step since it encompasses reproducing the designed product. The activities in this category are mainly physical and include welding, shaping, chamfering, cutting, grinding, measuring, joinery (screws and bolts), electrical, and hydraulics (Unwin, 2008). The fabrication process relies heavily on the sourcing of components to the boiler. The systems that have to be incorporated in the boiler design include the feed water heating, de-aerating, pumping, economizing, superheating, and condensing systems (Reese, 2003). These systems often have to be controlled, and the use of monitors to regulate the entry or exit of elements into the boiler system is elemental to the process. The fabrication process leads to the boiler, which must be put through quality checks to ensure functionality. Check for leaks, exposed electrical connections, delayed or non-functional responses and desired outputs are done to determine the suitability and completion of the project. This process engages the quality assurance department in checking for faults that are in the system, identifying them, and recommending a course of action to follow. The boiler system has to be put through test runs that mimic the extremes of the boiler purpose, where safe measures incorporated in the design are checked and/or recommended (Low, 2006). Upon completion of testing, the engineers are required to furnish the client with schedules information on repair and maintenance expectations, as well as troubleshooting information. Hazards i. Chemical Hazards Skin, eyes, and respiratory tract irritation: the use of hydrazine (as well as its derivatives) in boiler water causes irritation, upon severe exposure temporary blindness may occur (Lingard & Rowlinson, 2004). Coughing and upper respiratory irritation: caused by high sulphur fuels and sulfur dioxide inhalation (Rogers & Lincoln, 2009). Pneumoconiosis: exposure to vanadium, asbestos and fly ash dust, during repairs and insulation Dermatoses: caused by exposure to water additives and organic and/or organometallic corrosion inhibitors and fuels ii. Physical Hazards Extreme and incessant noise levels: a compilation of mechanical tools working on the metal exposes the workers to noise levels above 94 dBA (Friend & Kohn, 2010). Earmuffs and earplugs are recommended to counter the effect. Heat stress: caused by working in an area of high temperature caused by elements such as torches and relative humidity (Hatt, 2008). Proper aeration and the use of air conditioning systems are recommended for such a scenario. Radon exposure: underground boiler rooms are susceptible to radon exposure (Friend & Kohn, 2010). Authorized experts conduct tests on the probability of radon presence prior to construction of the manufacturing facility. Burns: An array of tools used in the manufacture process has heat as output energy, and contact may result in burns (Friend & Kohn, 2010). Using heat deterrent gloves recommended when working with a heat-emitting tool or around a hot surface. Allowing or aiding the surfaces and machines to cool down is another countermeasure. Cuts, punctures, and amputation: Sharp tools such as grinders, cutters, and sharp edges can lead to the hazard (Reese, 2008). Proper handling of tools and machines taught to all on a regular basis, with instructions and guidelines of the workshop incorporated in the working environment to serve as a reminder of safety. Explosions and fires: Sparks and heat from tools can lead to fires, and explosions considering the fuels and working conditions of the boilers (Reese, 2008). Ensuring flammable materials are kept away from potential sources of igniters, and having firefighting equipment near and around any potentially explosive situation. Falls and struck by falling objects: Mechanization of the manufacture process involves use of hydraulics and hoisting machines, which are a risk for the workers. Spills and slippery surfaces may also lead to falls (Reese, 2008). The hazard is avoided by ensuring rubber nonslip footwear (safety boots) are used in the workshop. Ensuring the floor is dry at all times is a requirement, and any spills should be dried immediately. Ensuring that workers wear hard cap helmets in the workplace to protect the head is necessary (Popplewel, 2009). Ensuring stability and secureness of lifted objects is demanded, with a warning of the intended transport encouraged. iii. Biological Hazards Fungi and Bacterial growth: boiler operation conditions may trigger the growth of bacteria and fungi, especially with vaporization of water. Rodents and insects: unkempt workplaces may attract vermin, which may cause infections and ailment. Workplace cleanliness and tidiness minimizes the chances of both biological hazards. In case of uncontrolled infestation, use of traps is encouraged (Smith, 2008). Literature review i. Asbestos associated diseases: Asbestos is an agent that may cause asbestos cancer and asbestos warts (Goetsch, 2014). Cancer affects the respiratory organs, while warts come from contact on the face. ii. Respiratory diseases: The production process releases numerous waste and harmful gases into the environment. Some of these wastes include welding fume, wood dust, ammonia gas, and iron galvanized fumes among others (Goetsch, 2014). Exposure to the waste could easily lead to a combination or one of the following respiratory conditions: asthma, benign pneumoconiosis, chronic bronchitis, (acute/chronic) hypersensitivity pneumonitis (HP), metal fume fever, polymer fume fever, and pulmonary edema, among others (Thompson, 2003). iii. Cancer: The workshop, considering the exposure to various hazards, can lead to several cancers. Cancers of the lungs, nasal passage, gastrointestinal, lymphatic, leukaemia and skin systems may develop from exposure to asbestos, diesel, silica, bio-aerosols, nickel, coal tar, hexavalent chromium, vinyl chloride, benzene, mineral wool, and UV light (Goetsch, 2014). iv. Neurological complications: The neurological system can be affected by the use of vibrating tools, exposure to lead, carbon monoxide, manganese, paints, degreasers, thinners, and chlorinated solvents, resulting in conditions such as hand-arm vibration syndrome, sub-acute toxic effect (lead), toxic neuropathy, Parkinson’s disease, and chronic solvent toxic syndrome (Goetsch, 2014). v. Skin Disorders: Allergic or contact dermatitis and contact urticarial are skin conditions that may occur from the exposure to hexavalent chromium, coal tar, epoxies, paints, degreasers, and glues, and animal dust respectively (Goetsch, 2014). vi. Miscellaneous Condition: Other disorders have been associated with working in an environment with all the mentioned hazards (Goetsch, 2014). Male infertility, gastroenteritis, Hantavirus, hepatitis, noise-induced hearing loss, renal disease, and asphyxiation are common disorders associated with working in such an industry. Methods The hazards identified in the discussions above concentrate on two categories of hazard mediums: air and surfaces. Sampling of the hazards for the two cases is done via air sampling and wipes sampling. The air sampling technique involves evaluating the ambient environment for toxins that have access to the respiratory system. This approach facilitates identification of the ventilation and control requirements, analyses the exposure before and after controls, determine the effectiveness of the ventilation systems, find potential exposure to inhaled chemicals, and establish is the worker’s exposure is within the exposure limits (Senn, 2000). The sampling should be done by a trained professional: Taking samples of the workers worst exposed (who), At the breathing zone (where), During periods when worst exposed, such as on each shift and during maintenance (when) Up to 10 hours provided the exposure does not change (how long) With 10% to 15% of workers exposed similarly taken (number of samples), and Facilitated by direct reading (equipment). The instruments used in the sampling include piston/bellows with changeable detector gas tubes, free-diffusion dosimeter badges, powered pumps, portable meters, and fixed monitoring systems. Wipe sampling is the other industrial approach to be used for sampling. It assesses the exposure that is risked via contact (skin absorption) or ingestion. The approach incorporates the visual and analytical approaches of evaluating exposure. The results are used in establishing the effectiveness of housekeeping, Personal Protective Equipment (PPE), PPE decontamination, and mitigation of contaminants among other programs. The sampling should be done as with the air sampling following a rule of thumb (10%- 15% of the workers in the worse exposed areas). The instruments that are used in this method include a glass fibre filter, (preferably white) paper filter, baby wipes, smear tab, and gauze pad (Senn, 2000). The dry instruments can be enhanced by wetting them in distilled water or other solvents developed to improve sample collection or sample identification. The process demands the use of a clean pair of disposable gloves worn for every sample, with the collected samples collected in a vial and analysed in the laboratory (Senn, 2000). The limitation of this sampling approach is that it only analyses the contact hazards, as air samples cannot be collected. The two sampling methods can be used to supplement the failures of the correspondent sampling technique. Figure 1: Process flow chart Source: Low, D. A. (2006). Manual of Machine Drawing and Design. New York: Read Books. References Bohle, P., & Quinlan, M. (2000). Managing Occupational Health and Safety: A Multidisciplinary Approach. South Yarra: Macmillan Education AU. Friend, M. A., & Kohn, J. P. (2010). Fundamentals of Occupational Safety and Health (5th Ed.). Maryland: Government Institutes. Goetsch, D. L. (2014). The Basics of Occupational Safety (2nd Ed.).New Jersey: Pearson Education. Hatt, W. K. (2008). Laboratory Manual of Testing Materials. New York: BiblioBazaar. Henry, A. (2009). Handbook for Mechanical Engineers. New York: BiblioBazaar. Lingard, H., & Rowlinson, S. (2004). Occupational Health and Safety in Construction Project Management. Madison: Routledge. Low, D. A. (2006). Manual of Machine Drawing and Design. New York: Read Books. Metcalf, W. (2008). Steel: A Manual for Steel Users. New York: BiblioBazaar. Popplewel, W. C. (2009). Experimental Engineering -, Volume 2. New York: Ind Press. Reese, C. D. (2003). Occupational Health and Safety Management: A Practical Approach. Boca Raton, Florida: CRC Press. Reese, C. D. (2008). Industrial Safety and Health for Goods and Materials Services. Boca Raton, Florida CRC Press. Rogers, W., & Lincoln, M. J. (2009). Rogers Machinists Guide - A Practical Illustrated Treatise on Modern Machine Shop Practice. New York: Read Books. Senn, E. (2000). Controlling Chemical Exposure; Industrial Hygiene Fact Sheets. Trenton, NJ: New Jersey Department of Health and Senior Services. Smith, C. A. M. (2008). A Handbook of Testing. New York: Read Books. Thompson, L. A. (2003, Feb.). An Industrial Hygiene Sampling Strategy To Quantify Employee Exposure. WM ’03 Conference, 1 -10. Tucson, Arizona. Unwin, C. W. (2008). The Elements of Machine Design. New York: BiblioBazaar. Read More