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Combustible Dust

LIMITING WORKER STYRENE EXPOSURE. Combustible Dust. Composites Manufacturing Issues. Bob Lacovara, CCM, CCT-I Convergent Composites. Styrene Exposure Reduction. Elements of. Exposure Control. Molding Process. PPE. Engineering Controls. Materials Selection.

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Combustible Dust

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  1. LIMITING WORKER STYRENE EXPOSURE Combustible Dust Composites Manufacturing Issues Bob Lacovara, CCM, CCT-I Convergent Composites

  2. Styrene Exposure Reduction Elements of Exposure Control Molding Process PPE Engineering Controls Materials Selection

  3. Styrene Exposure Reduction Materials Technology Polyester Resin EPOXY RESIN

  4. Styrene Exposure Reduction Materials Technology • Styrene Suppressants

  5. Styrene Exposure Reduction Materials Technology • Styrene Suppressants • Low Styrene Resins LS Polyester Resin

  6. Styrene Exposure Reduction Materials Technology • Styrene Suppressants • Low Styrene Resins • Alternative Monomers

  7. Styrene Exposure Reduction Materials Technology • Styrene Suppressants • Low Styrene Resins • Alternative Monomers • Epoxy Resins EPOXY RESIN

  8. Styrene Exposure Reduction Materials Technology • Styrene Suppressants • Low Styrene Resins • Alternative Monomers • Epoxy Resins • Thermoplastics

  9. Styrene Exposure Reduction Emissions Limiting Processes

  10. Styrene Exposure Reduction Process Technology • Non-Spray Application

  11. Styrene Exposure Reduction Process Technology • Non-Spray Application • Vacuum Infusion

  12. Styrene Exposure Reduction Process Technology • Non-Spray Application • Vacuum Infusion • RTM Processing

  13. Styrene Exposure Reduction Process Technology • Non-Spray Application • Vacuum Infusion • RTM Processing • Pre-Preg Processing

  14. Styrene Exposure Reduction Process Technology • Non-Spray Application • Vacuum Infusion • RTM Processing • Pre-Preg Processing • Polyester Pre-Preg

  15. Styrene Exposure Reduction Process Technology • Non-Spray Application • Vacuum Infusion • RTM Processing • Pre-Preg Processing • Polyester Pre-Preg • Robotic Application

  16. Styrene Exposure Reduction Control Technology

  17. Styrene Exposure Reduction Control Technology • Best Practice Ventilation

  18. Styrene Exposure Reduction Control Technology • With general ventilation (aka, dilution ventilation) • it will be difficult to produce a 20 ppm environment • Enhanced ventilation will be required in most cases • to technically and cost effectively address 20 ppm

  19. Styrene Exposure Reduction General Ventilation Dilution ventilation moves the entire volume of air within a work space

  20. Styrene Exposure Reduction Enhanced Ventilation Designed to move air specifically from breathing and emissions producing zones

  21. Styrene Exposure Reduction Control Technology • Enhanced Ventilation Example Filament Winding Application

  22. Styrene Exposure Reduction Control Technology • Enhanced Ventilation Example Open Molding Application

  23. Styrene Exposure Reduction Control Technology • Enhanced Ventilation Example Hull Molding Application

  24. Styrene Exposure Reduction Work Practice Control C1T1 + C2T2 + C3T3 Exposure = 8 Hrs

  25. Styrene Exposure Reduction Work Practice Control • Clean Operations Training

  26. Styrene Exposure Reduction Work Practice Control • Clean Operations Training • Operator Positioning

  27. Styrene Exposure Reduction Operator Positioning Air Flow Operator Positioned Upwind Spray Booth

  28. Styrene Exposure Reduction Administrative Control • Work Habit Training • Operator Positioning • Time Limited Exposure

  29. Styrene Exposure Reduction Administrative Control TWA Calculation C1T1 + C2T2 + C3T3 Exposure = 8 Hrs Exposure = Time Weighted Avg (TWA) C = Concentration (ppm) T = Time (hours)

  30. Styrene Exposure Reduction • Measured Exposure: • 2-hours @ 70 ppm • 2-hours @ 50 ppm • 4-hours @ 40 ppm TWA Calculation (50 ppm TWA) (70 x 2) + (50 x 2) + (40 x 4) 400 = = 50 ppm TWA 8 8 Hrs

  31. Styrene Exposure Reduction • Measured Exposure: • 2-hours @ 50 ppm • 2-hours @ 30 ppm • 4-hours @ 0 ppm TWA Calculation (20 ppm TWA) (50 x 2) + (30 x 2) + (0 x 4) 160 = = 20 ppm TWA 8 8 Hrs

  32. Styrene Exposure Reduction TWA Calculation Proposed 20 ppm TWA looks like this: Current 50 ppm TWA looks like this: • Measured Exposure: • 2-hours @ 70 ppm • 2-hours @ 50 ppm • 4-hours @ 40 ppm • 400 ppm units/day • Measured Exposure: • 2-hours @ 50 ppm • 2-hours @ 30 ppm • 4-hours @ 0 ppm • 160 ppm units/day

  33. Styrene Exposure Reduction Time Limited Exposure Scenario: Four Workers - Three Different Jobs

  34. Styrene Exposure Reduction The Reality of Crew Rotation 4-Workers / 3-Jobs - Spraying - Laminating - Finishing 50 ppm - 2 hrs / 30 ppm - 2 hrs / 0 ppm - 4 hrs 2Hr. Cycle 1 2Hr. Cycle 2 2Hr. Cycle 3 2 Hr. Cycle 4 • Worker A - Spray • Worker B - Roll Out • Worker C - Finish • Worker D - Finish • Worker B - Spray • Worker A - Roll Out • Worker C - Finish • Worker D - Finish • Worker C - Spray • Worker D - Roll Out • Worker A - Finish • Worker B - Finish • Worker D - Spray • Worker C - Roll Out • Worker A - Finish • Worker B - Finish

  35. Styrene Exposure Reduction SUMMARY: An exposure limit of 20 ppm TWA will require a combination of technologies & work practices • Low emissions materials • Emissions limiting processes • Enhanced ventilation • Enhanced work practices

  36. LIMITING WORKER STYRENE EXPOSURE Combustible Dust Composites Manufacturing Issues Contact: Bob Lacovara, CCM, CCT-I Convergent Composites blacovara@aol.com www.convergentcomposites.com

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