DOE/MC/32260 -- 5840

(DE98002045)

Ultra-High Pressure Water Jet: Baseline Report

Topical Report WECES VED

July 31,1997

19980402 039
Work Performed Under Contract No.: DE-FC21-95MC32260

For

U.S. Department of Energy U.S. Department of Energy

Office of Environmental Management Office of Fossil Energy
Office of Technology Development Federal Energy Technology Center
1000 Independence Avenue Morgantown Site
Washington, DC 20585 P.O. Box 880
Morgantown, West Virginia 26507-0880

BY
Operating Engineers National Hazmat Program
250 Airport Circle
Beaver, West Virginia 258 13
DTIC QUALrm &-;-ccmD g
 Disclaimer

This report was prepared as an account of work sponsored by an

agency of the United States Government. Neither the United States
Government nor any agency thereof, nor any of their employees,
makes any warranty, express or implied, or assumes any legal liability
or responsibility for the accuracy, completeness, or usefulness of any
information, apparatus, product, or process disclosed, or represents
that its use wo,uld not infringe privately owned rights. Reference
herein to any speciiic commercial product, process, or service by trade
name, trademark, manufacturer, or otherwise does not necessarily
constitute or imply its endorsement, recommendation, or favoring by
the United States Government or any agency thereof. The views and
opinions of authors expressed herein do not necessarily state or reflect
those of the United States Government or any agency thereof.
 ULTRA-HIGH PRESSURE WATER JET

TABLE O F CONTENTS

SECTION 1 SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
TECHNOLOGY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
KEYRESULTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

SECTION 2 -TECHNOLOGY DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Systemoperation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

SECTION 3 .HEALTH AND SAFETY EVALUATION . . . . . . . . . . . . . . . . . . . . . . . . . 3

General Health and Safety Concerns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Industrial Hygiene Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Job Safety Analysis (JSA) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Failure Modes and Effects Analysis (FMEA). . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Technology Safety Data Sheet (TSDS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
'Human Factors Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Emergency Response/Preparedness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

SECTION 4 .TECHNOLOGY APPLICABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

SECTION 5 .REGULATORY/POLICY ISSUES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Core Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
c Technology-specific Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Best Management Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Special requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Core Training Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Special Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Best Management Practices Training . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

SECTION 6 .OPERATIONAL CONSIDERATIONS AND

RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

APPENDIX A .REFERENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

APPENDIX B .INDUSTRIAL HYGIENE DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

 ULTRA-HIGHPRESSURE WATER JET
HUMAN FACTORS EVALUATION

SECTION 1 - SUMMARY

Technology Description

The ultra-high pressure waterjet technology was being evaluated at Florida

International University (Flu) as a baseline technology. In conjunction with Flus
! evaluation of efficiency and cost, this report covers the evaluation conducted for safety
and health issues. It is a commercially available technology and has been used for

1 various projects at locations throughout the country.

The ultra-high pressure waterjet technology acts as a cutting tool for the removal of

I. surface substrates. The HuskyTMpump feeds water to a lance that directs the high
pressure water at the surface to be removed.

P Key Results

The safety and health evaluation during the testing demonstration focused on two main
I areas of exposure. These were dust and noise. The dust exposure was found to be
minimal, which would be expected due to the wet environment inherent in the
! technology, but noise exposure was at a significant level. Further testing for noise is
I recommended because of the outdoor environment where the testing demonstration
took place. In addition, other areas of concern found were arm-hand vibration,
ergonomics, heat stress, tripping hazards, electrical hazards, lockouthagout, fall
I hazards, slipping hazards, hazards associated with the high pressure water, and
hazards associated with air pressure systems.

I
I
1
 SECTION 2
I

TECHNOLOGY DESCRIPTION

SYSTEM OPERATION

The ultra-high pressure waterjet technology was being evaluated at Florida

International University (Flu)as a baseline technology. In conjunction with FIUs
evaluation of efficiency and cost, this report covers the evaluation conducted for safety
and health issues. It is a commercially available technology and has been used for
various projects at locations throughout the country.

The Huskym is an ultra-high-pressurewaterjet cutting tool. The pump is mounted on a

steel tube frame which includes slots for transport by a forklift.
Utility interface connections are located on the rear bulkhead.
The husky also features an automatic shutdown for low oil
pressure, high oil temperature, or low inlet pressure, an in-line
water filter to remove particles larger than 5 microns, a safety
valve to relieve system pressure when over-pressure conditions
occur, a triplex high pressure pump, and red or amber sensor
lights that illuminate for a shutdown condition.

The system requires a water supply of 6 gallons per minute.

The pump inlet water is routed through a 5 micron water filter to
the pump inlet check valves. During the intake stroke of the
Figure 1- Operator and pump, water enters the cylinder. A the end of this stroke the
waterjet lance. inlet check valve closes. On the pressure stroke, the plunger
pressurizes the water until the outlet check valve opens. At the
end of the pressure stroke, the outlet valve closes and the cycle is repeated.

Placement of the HuskyTMmust allow for a three foot

clearance on all sides for operation and service
access. At maximum continuous operation, the output
volume is 7.2 gallons per minute with an output
pressure of 40,000 psi. A diesel engine provides
power for the system.

The operator of the waterjet did not encounter

difficulties with equipment operation while dressed out Figure 2 -The pump.
in the appropriate PPE. The operator of the HuskyTM
did experience some difficulty during maintenance
activities due to decreased visibility and a decrease in tactile sensitivity in the

2
 1

hands/fingers. The technology did present a significant noise hazard. These as well as
other safety and health factors will be discussed in greater detail in other sections of
this report.

SECTION 3
HEALTH AND SAFETY EVALUATION

General Safety and Health Concerns

Personnel where the ultra-high pressure water jet technology is being used need to be
concerned with safety and health issues. Issues that personnel need to be cognizant of
may be divided into two categories. Core issues are those that are based on current
safety and health regulatory requirements. Best management practices are related to
issues that are not based on current safety and health regulations but are key elements
in preventing worker injury and illness on the job.

Safety and health issues of concern with the ultra-high pressure water jet technology
included:

+ Tripping hazards - the high pressure lines, water lines (a garden hose), and air
lines needed to operate the equipment, while necessary, are tripping hazards,
therefore, the need for stringent housekeeping must be evaluated.

+ Electrical hazards - the electrical system in the HuskyTMcan present electrical

hazards, therefore, the need for ground fault circuit interrupters and grounding
must be evaluated. If there are any electrical sources in the area where the high
pressure water is being used, they would be a hazard and would need to be de-
energized in accordance with lockoufftagout procedures.

+ Fall hazards - the HuskyTMwas located on a truck bed during the testing
demonstration. The truck bed sat approximately four feet above the ground.
This presented a fall hazard and the truck bed needs to have railings. In
addition, the vertical ladder on the truck bed did not have any hand rails and
therefore, did not allow the worker to maintain three points of contact while
climbing. Hand rails need to be placed on the ladder.

Lockoutrragout - the user of the technology will need to develop a lockoufftagout

program to assure there is not an accidental release of energy during
maintenancehepair activities.

+ Heat stress - the operators of the waterjet and the pump were subjected to an
increase in heat stress due to the need to utilize Anti-C PPE and /or splash

3
 (water resistant) PPE. The user will need to develop a heat stress program for
the environment in which the technology is being used, taking into consideration
any PPE that may need to be utilized.

4 Ergonomics - the user was subjected to some ergonomic stressors that need to
be taken into consideration, such as, stooping, bending, twisting, kneeling, and
lifting. The lance added a constant weight in the hands of the operator. This will
add to the stress placed on the lower back and to the upper body. In particular,
fatigue of the arms and upper body.

4 Arm-hand vibration - the waterjet operator was subjected to arm-hand vibration

while operating the equipment. The support handle on the lance was
constructed of a hard rubber material. This placed increased stress on the hand.
A softer material would place less pressure on the hand. The trigger on the
lance for the waterjet was made of metal and was designed for single finger
operation. This will put stress on the index finger and could lead to problems
such as trigger finger. A trigger design that uses several fingers and is designed
with a cushion over the metal would be a better choice.

4 Whole-body vibration - the platform (truck bed) on which the HuskyTMwas

mounted was a source of whole-body vibration during operation. The operator is
required to stay with the pump and therefore, would be exposed to vibration
throughout the day.

4 Noise - the user is subjected to a significant amount of noise while operating the
water lance. The operator of the HuskyTMis also subjected to a significant
amount of noise during operations.

4 Dust - due to the wet operating environment, dust was not a significant problem
during operation. The spread of contaminant, however, was of concern. The
waterjet created a situation where grit (small pieces of water blasted concrete)
were sprayed up to fifty feet from the point where the waterjet was in contact with
the concrete. The water spray and the spray of concrete created a spread of
contaminant that was evident on other surfaces and the PPE of the operator.
Water run off was also a problem for the spread of contaminant. There is
potential for dust to be left on the surface after the water dries and this can
present an inhalation exposure if the dust is disturbed.

4 Diesel Exhaust - the HuskyTMuses a diesel engine for operation. If the pump
was being used indoors, it could create an exposure situation for diesel fumes
and of particulgr concern carbon monoxide. Even in an outdoor testing situation,
such as the testing demonstration, depending on the wind direction, there is
potential for exposure to the diesel fumes.

4
+ Struck by hazards (from concrete) - The waterjet created a situation where grit
(small pieces of blasted concrete) was sprayed up to fifty feet from the point
where the waterjet was in contact with the concrete. The water spray and the
spray of concrete created a spread of contaminant that was evident on other
surfaces and the PPE of the operator. The flying pieces of concrete presented a
severe eye hazard. A splash suit or a water resistant Anti-C suit would not
provide enough protection against puncture from flying debris. A Saranex
coated Tyvek or a level B PVC suit may be required. Additionally, safety glasses
may not be protective enough and goggles need to be worn under a face shield.

+ Slipping hazard - the water and waterkoncrete debris created an extremely

slippery surface. This included not only the surface where the operator was
working but adjoining surfaces as well.

+ Compressed air - the use of compressed air created tripping hazards from the air
line. In addition, there is the potential for injury from the compressed air itself or
the air hoses if an accidental disconnect, rupture, or leak occurs.

+ High pressure water - the use of high pressure water created tripping hazards
from the water supply and discharge lines. In addition, there is potential for
injury from the high pressure water jet or high pressure water lines if an
accidental disconnect, rupture, or leak occurs. There is a severe hazard created
by the water being discharged at the head of the lance. If the operator were to
hit hidher leg, foot, or any other body part with the waterjet, there is potential for
a severe laceration or even amputation.

+ Communication - due to the noise generated by the technology during operation

and the distance between the waterjet lance operator and the pump operator,
communication was difficult. Personnel working in the area should be familiar
with and use hand signals when needed. If the lance is being used inside an
enclosure and the pump is outside, radio communication is needed but would be
difficult during operation due to the noise levels. In this case, other types of
signals such as flashing lights may need to be employed.

5
 INDUSTRIAL HYGIENE MONITORING

During the current testing demonstration with the high pressure water system, sampling
was conducted for dust and noise. In addition, the wet-bulb globe temperature was
monitored to evaluate heat stress. Observational evaluation was conducted for
'I
i
ergonomics, arm-hand vibration, and whole-body vibration.

Through general observational techniques the potential for ergonomic problems was
evaluated during the testing demonstration. There is potential for muscle/back stress
and/or injuries due to bending, twisting, and lifting associated with the setup, operation,
maintenance, and decontamination of the equipment. The greatest potential for back
stress is during operation of the lance. The operator was using the longest lance
available and still had to stoop constantly to reach the surface and control the
backpressure from the lance, There was stress placed on the upper body from
operating the lance and stress on the legs from standing in one position for an
extended period of time while maintaining the lance in the correct position with the
backpressure being exerted.

During the testing demonstration arm-

hand vibration was present. While arm-
hand vibration was not quantitatively
measured, it was readily apparent that
there was exposure to arm-hand
' I
vibration during operation of the waterjet
lance that could potentially cause
problems such as Raynaud's syndrome.
The support handle on the lance was
constructed of a hard rubber material.
This placed increased stress on the
Figure 3- Waterjet in use. hand. A softer material would place less
pressure on the hand. The trigger on
the lance for the waterjet was made of metal and was designed for single finger
operation. This will put stress on the index finger and could lead to problems such as
trigger finger. A trigger design that uses several fingers and has a cushion over the
metal would be a better choice. Whole-body vibration was a concern for the operator of
the HuskyTMpump. The platform (truck bed) on which the pump was mounted vibrated
constantly during operation.

Heat stress was monitored using a Quest QuestTemp" 15 Heat Stress Monitor. The
wet-bulb globe temperature was used to determine the worklrest regimen in
accordance with the American Conference of Governmental Industrial Hygienist
(ACGIH) recommendations. The wet-bulb globe temperature was adjusted for the type
of clothing, including PPE, that the worker was wearing.

6
 In addition, the worker's blood pressure, pulse, and temperature were monitored
throughout the day. No problems were encountered due to heat stress but the worker's
comfort level was increased when not wearing the Anti-C PPE, Saranex coated Tyvek,
or splash suit. While heat stress will be increased when wearing PPE, the overall heat
stress response will vary from worker to worker. Each situation in which the current
technology is used will need to be evaluated for the heat stress potential taking into
consideration the wet-bulb globe temperature, PPE in use, physical condition of tHe
worker, and amount of worker acclimatization.

Dust monitoring was conducted with a sampling train consisting of an SKC IOM
lnhalable dust sampler coupled with a MSA Escort Elf air sampling pump. Pre- and
post sampling calibration was accomplished using a BIOS International DryCal DCI
primary calibration system. Sampling filters were desiccated pre- and post sampling
and weighed on a Denver Instrument Company A-200DS scale. Sampling was
conducted in accordance with NIOSH method 0500.

Personal sampling was conducted on the equipment operator and the pump operator.
Personal dust sampling results of 2.0 mg/m3and 84.1026 mg/m3for the water lance
operator and 0.0 mg/m3and 0.7874 mg/m3were obtained for the pump operator. One
of these values (84.1026 mg/m3)exceeds the Occupational Safety and Health
Administration (OSHA) permissible exposure limit (PEL) and the ACGIH threshold limit
value (TLV) of 15 mg/m3and I O mg/m3respectively for total dust. There was not any
visible dust generated during operation due to the wet environment inherent in the
process. The extremely high value of 84.1026 mg/m3appearedto be due to the
accumulation of grit on the filter of the inhalable dust sampler. While not a dust
problem, this illustrates the ability of the technology to spread contamination into the
breathing zone of the operator. The grit itself could become an ingestion hazard. This
indicated a potential need for PPE other than a face shield and safety glasses such as
a full face respirator. A complete sampling plan for a site would need to be developed
to include not only dust but other contaminants specific to the concrete decontamination
project. See Appendix B for sampling data.

Personal noise monitoring was conducted using Metrosonic db-3100 data logging noise
dosimeters. Calibration was conducted pre- and post monitoring using a Metrosonic
CL304 acoustical calibrator. Monitoring was conducted on the HuskyTMpump operator
for 2.05 hours (123 minutes) and again for 7.86 hours (472 minutes) during operation of
the waterjet system. Monitoring during this time showed a noise dose of 16.54% which
gives an 8-hour time-weighted average (TWA) of 77.0 dBA and 108.21% which gives
an 8-hour TWA of 90.5 dBA. If the pump operator continued to have the same level of
noise exposure during the 8-hour shift a projected 8-hour TWA would produce a noise
dose of 64.37% or an 8-hour TWA of 86.8 dBA and 133.74% or an 8-hour TWA of 92.1
dB respectively.

7
Monitoring conducted on the lance operator was conducted for 7.88 hours (473
minutes) during operation of the waterjet system. Monitoring showed a noise dose of
875.1% which gives and 8-hour TWA of 105.6 dBA. If the lance operator continued to
have the same level of noise exposure during the 8-hour shift a projected 8-hour TWA
would produce a noise dose of 1135.73% or an 8-hour TWA of 107.5 dBA.

The OSHA allowable PEL for noise is a 100% dose or an 8-hour TWA of 90 dBA. The
operator of the pump was not overexposed after 2.05 hours of operation and borderline
for overexposure after 7.86 hours of operation. The lance operator was overexposed
after 7.88 hours or operation. At these exposure levels, personnel would be required to
be included in a hearing conservation program. Feasible engineering controls,
administrative controls, and personal protective equipment (PPE-hearing protection
devices) need to be used. The percentage of time spent at each loudness level (for the
two significant exposures) that comprises the exposures can be seen in Appendix B.
For the pump operator, 28.3% of the time the noise exposure was less than 85 dBA
which means that the majority of the time or 71.I % of the time the noise exposure was
at sound levels above 85 dBA. For the lance operator, 21.637% of the time the noise
exposure was less than 85 dBA which means that the majority of the time or 78.363%
of the time the noise exposure was at sound levels above 85 dBA. As can be seen on
the graphs, the time spent over 85 dBA for the lance operator was at a much higher
decibel level than that for the pump operator. OSHA requires that a hearing
conservation program be initiated if the 8-hour TWA is 85 dBA.

During the 7.86 hours of operation for the pump operator, the noise levels were
averaged for each one minute period of time and then an overall average of each one
minute period was calculated which gave an average exposure level of 92.2 dBA for an
80 dB cutoff level and 91.3 dBA for a 90 dB cutoff level. The average exposure level
for the lance operator was 107.5 dBA for an 80 db or a 90 db cutoff level. OSHA
requires an 80 db cutoff for hearing conservation measurements and a 90 db cutoff for
engineering control compliance measurements. The maximum sound level observed
during the measurement period was 108.6 dBA for the pump operator and 121.9 dB for
the lance operator and the highest instantaneous sound pressure level was 137.7 dB
for the pump operator and 140.6 dB for the lance operator.

These measurements define noise as a significant exposure for personnel operating

the HuskyTMpump and the waterjet lance. It must also be noted that the equipment
was being operated in an open outdoor environment at the time of the measurements
and operation in an enclosed facility would have the potential to increase the noise level
due to other influences such as vibration and reverberation, therefore, it is
recommended that noise monitoring be conducted while the equipment is being
operated in an enclosed environment.

8
 JOB SAFETY ANALYSIS
ULTRA-HIGH PRESSURE WATER JET

*Use of hand protection

*Use of proper hand tools for the job
*Awareness of the specific hazards
*Organization of materials
(housekeeping)
*Walking around areas that are
wetlslippery when possible
*Walking around tripping hazards when
possible

*Awareness of where equipment is

being moved to at all times
*Prohibit worker from being
between moving and stationary
objects at all times
*Keep personnel clear of moving
obiects
~

*Place side rails on any elevated

platforms where the pump is located

r
*Place hand rails on the ladder for the
platform

Muscular/Back Injury *Ergonomics training including safe lifting

techniques
*Use of equipment such as forklift or
crane for unloading

9
 Electrical Hazards *Assure worker properly trained in
electrical safety
*Assure all equipment properly grounded
and use of ground fault circuit
interrupters

ER LANCE
Exposure to contaminant *Wear proper PPE and respiratory
protection - may need additional gloves
over anti-C gloves to avoid tears and rips
to them
*Have something to sit or kneel on so do
not have additional personnel exposure
from sitting or kneeling on contaminated
surface

I Accidental activation of waterjet *Use proper lockoutltagout procedures

* Awareness of the specific hazards

* Organization of materials
(housekeeping)
Walking around areas that are wet
!slippery when possible
Walking around tripping hazards when
oossible

I PUMP OR WATER LANCE

Wear proper PPE and respiratory
wotection - may need additional gloves
wer anti-C gloves to avoid tears and rips
:o gloves

I Muscle/Back Strain Training in ergonomics for proper

:echniques for lifting, twisting, bending

10
Exposure to oils and hydraulic fluids *Wear proper PPE - may need PPE in
addition to Anti-C PPE

Accidental activation of moving parts *Use proper lockoutltagout techniques

\.
(pinch points)
OPE F
Fall to Below *Place side rails on any elevated
platforms where the pump is located
*Place hand rails on the ladder for the
platform
*Where the pump extends to the edges
of the platform, do not walk around the
pump - have ladder access at different
points on the platform
Pinch Points *Use of hand protection
*Use of proper hand tools for the job
Muscular/Back injury *Ergonomics training to include proper
techniques for lifting, bending
ahole-body vibration Ergonomic training with emphasis in
uhole-body vibration
Assess pump and platform it is mounted
3n for the use of anti-vibration
mgineering controls.
Exposure to contaminant Use of proper PPE and respiratory
Drotection
Exposure to noise Assess tool for possible engineering
:ontrols for noise
Use of proper hearing protection devices
Worker included in a hearing
:onsetvation program
. -

OPERATION OF VI LTERJET LANCE

Muscular/Back Injury Ergonomics training to include proper
:echniques for lifting, bending, static
sosturing

11
IExposure to contaminants *Wear proper PPE and respiratory
~~ ~ ~~~~

protection
Exposure to noise *Assess lance for possible engineering
controls for noise
*Use of proper hearing protection device:
*Worker included in a hearing
conservation program
Exposure to high pressure water and/or *Wear appropriate PPE including steel
concrete debris toe/shank boots and leg guards
*Wear goggles with face shield
* Shield front of lance
~

Slips/Trips/Falls (water debris makes * Awareness of specific hazards

surface very slippery) * Organization of materials
(housekeeping)
* Walking around areas that are wet or
slippery when possible
* Walking around tripping hazards when
possible.
Spread of Contamination * Contain concrete/water spray and water
runoff
* Shield front of lance

I Communication problems due to noise

levels
* Use hand signals as part of SOP'S

I Visibility problems due to fogging of face ' Use anti-fogging treatment on face

I
shield shield
Dust (after water dries) ' Cleanup water/debris/contamination
iefore drying

12
 FAILURE MODES AND EFFECTS ANALYSIS
ULTRA-HIGH PRESSURE WATER JET

RE MODE
1
Lose water pressure *System will shut down
*Potential for strain on muscles, in
particular of the back, if sudden shut
down because of static posturing and
stooping against water back pressure.

Hydraulic line comes loose (fitting fails) or *Potential for worker exposure to
puncture/rupture hydraulic fluid under high pressure which
could lead to severe injury from the hose
itself and/or the fluid and exposure to the
fluid

Lose power (run out of fuel) *Equipment shuts down

Potential for strain on muscles, in
particular of the back, if sudden shut
down because of static posturing and
stooping against water back pressure.

High pressure water line comes loose or Potential for severe injury from
puncture/rupture 3ersonnel being contacted by high
3ressure water or the line itself
Potential for uncontrolled water spray to
:ause contaminant to be spread

13
 I
1
Air line comes loose or puncture/rupture *Potential for severe injury from
personnel being contacted by high
pressure air or line itself I
I
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1
1
1
1

14
 TECHNOLOGY SAFETY DATA SHEET
ULTRA-HIGH PRESSURE WATER JET

r
I SECTION I:TECHNOLOGY IDENTITY
Manufacturer's Name and Address: Emergency Contact:
Bill Packet
P.W. Stephens Environmental Company (314)421-3366
1525 South Eighth Street
St. Louis, MO 63104
Information Contact:
Bill Packet
(314)421-3366
Date Prepared:

Other Names: High Pressure Water Signature of Preparer:

SECTION 2: PROCESS DESCRIPTION

The HuskyTMis an ultra-high pressure water jet cutting tool. The pump is mounted on
a steel tube frame which includes slots for transport by a forklift. Utility interface
connections are located on the rear bulkhead. The HuskyTMalso features an
automatic shutdown for low oil pressure, high oil temperature, or low inlet pressure,
an in-line filter to remove particles larger than 5 microns, a safety valve to relieve
system pressure when over-pressure conditions occur, a triplex high pressure pump,
and red or amber sensor lights that illuminate for a shutdown condition.

The system requires a water supply of 6 gallons per minute. The pump inlet water is
routed through a 5 micron water filter to the pump inlet check valves. During the
intake stroke of the pump, water enters the cylinder. At the end of this stroke the inlet
check valve closes. On the pressure stroke, the plunger pressurizes

15
 the water until the outlet check valve opens. At the end of the pressure stroke, the
outlet valve closes and the cycle is repeated.
Placement of the HuskyTMmust allow for a three foot clearance on all sides for
operation a n d service access. At maximum continuous operation, the output volume
is 7.2 gallons per minute with an output pressure of 40,000 psi. A diesel engine
provides power for the system.

SECTION 3: PROCESS DIAGRAM

The diagram illustrates the Huskym pump. A complete process diagram to include
the water jet w a s not available from the manufacturer.

I 913.0"
(2413.9 cm)
I

16
 SECTION 4: CONTAMINANTS AND MEDIA
The technology has the potential to cause concrete associated contaminants to be
sprayed up to fifty feet from the point of contact by the water jet. Specific
contaminants need to be evaluated on a site by site, job by job basis to determine the
potential for exposure.
1 I

I SECTION 5: ASSOCIATED SAFETY HAZARDS

Probability of Occurrence of Hazard:
I Hazard may be present but not expected over background level
2 Some level of hazard above background level known to be present
3 High hazard potential
4 Potential for imminent danger to life and health

Technology has the potential to present electrical hazards. Assure proper grounding
of all equipment. Compliance with applicable electrical standards and codes and
lockoutltagout procedures must be followed to assure the safety of personnel.

The water jet does not pose a fire and explosive hazard. The HuskyTMpump is
powered by a diesel engine which does have the potential to become a fire and
explosive hazard.

!
\

Not part of this technology unless the specific location where water jet is being used
i is a confined space. In this case, confined space procedures would need to be
followed. This technology would be difficult to use in a confined space due to the
spray of water and contaminant and the use of a diesel-powered pump.

Use of the Huskym pump may pose the following: pinch points, struck by, and
caught between hazards and fall from above.
 ISECTION 5: ASSOCIATED SAFETY HAZARDS

Technology presents a serious hazard from high-pressure water and air. There is
potential for severe injury from the water, which could lacerate or amputate parts of
the human body.

IAir lines and water lines present tripping hazards

The platform the pump resides on presents a fall hazard if it is elevated without
railings. Ladders to an elevated platform present a fall hazard if they do not have
handrails in order to maintain 3 points of contact while climbing.

The presence of multiple pieces of mobile equipment (which may be needed to

unload and load the technology) in relationship to a small area of operation may pose
a significant danger. Sufficient warning devices such as horns, bells, fights and back
up alarms should be utilized. Personnel should be trained to work with and around
moving equipment.

RISK RATING: N/A

Not part of this technology.

Not part of this technology.

INot part of this technology.

I Not part of this technology.

18
 SECTION 5: ASSOCIATED SAFETY HAZARDS
i

Unloading and loading of technology may require overhead lifts or the use of a
I forklift. Proper precautions indicated.

Would only be present if a crane or forklift were required to unload or load equipment.

SECTION 6: ASSOCIATED HEALTH HAZARDS

Technology did not produce dust from the concrete and concrete contamination due
to the wet operational environment. After the water dries dust could be left on the
surface which may become an inhalation hazard if disturbed. Specific hazards will
be identified from the site characterization. Diesel fumes from the Huskym could
present a hazard.

This would be dependent on the contaminants at the site and would be identified by
the site characterization. Hydraulic fluid could present a hazard.

Ambient atmospheric conditions correlated with PPE levels must 'be considered.

The water jet and the pump present a high noise hazard.

None associated with this technology.

'1
19
SECTION 6: ASSOCIATED HEALTH HAZARDS I
None associated with this technology but the contaminated concrete may present a
sianificant radiation exposure. This will be identified by the site characterization. I
Technology does not produce a hazard, but ambient conditions need to be
considered. I
Poses ergonomic hazards associated with lifting, bending, twisting, stooping,
kneeling, and static posturing. These may cause injurykitrain to the back, knees,
hips, and/or leas.

Operation of the water jet lance poses a hazard due to arm-hand vibration. This may
lead to associated problems such as Raynaud's Syndrome. Additionally, the pump
operator may be exposed to whole-body vibration depending on the platform where
the pump is located.

SECTION 7: PHASE ANALYSIS I

The set-up/start-up phase presents several hazards including pinch points,
slips/trips/falls, struck by/caught between, falling from above, fall to below,
muscular/back injury, and electrical.

The operational phase presents several hazards including exposure to contaminant

(airborne and from the surface), exposure to diesel fumes, hazards associated with
high pressure water and air lines, arm-hand vibration, whole-body vibration,
muscular/back injury, and exposure to noise. Fall hazards may also be associated
with operation of HuskyTMdepending on what type of surface it is mounted.

20
I SECTION 7: PHASE ANALYSIS I
The maintenance phase presents several hazards including pinch points,
slips/trips/falls, struck bykaught between, muscular/back injury, electrical, exposure
to contaminants (airborne and from the surface), exposure to hydraulic fluids and
diesel fumes, and accidental activation of moving parts.

The decommissioning phase presents several hazards including exposure to the

contaminant, pinch points, slips/trips/falls, and muscular/back injury.

SECTION 8: HEALTH AND SAFETY PLAN REQUIRED ELEMENTS

When concrete is removed using a high pressure water jet, dust is not a problem but
the spraying of pieces of concrete and possibly other contaminants is highly
probable. There may be dust left after the water dries and if disturbed it may become
a hazard. Specific needs must be assessed for each job to determine what
monitoring needs to be conducted. Monitoring also needs to be done for specific
concrete contaminants and may need to be conducted for specific constituents of the
concrete such as silica. In addition, noise monitoring is essential.

Trainings that would apply in this case may include but not be limited to:
HAZWOPER (Hazardous Waste Operations and Emergency Response), HAZCOM
(Hazard Communication), Respiratory Protection, Hearing Conservation, Ergonomics
(proper lifting, bending, stooping, kneeling, arm-hand vibration), Heat stress (learning
to recognize signs and symptoms), Personal Protective Equipment, Job specific
training for equipment operation, CPR/First Aid/Emergency Response/Blood borne
Pathogens, Electrical Safety, LockouVTagout, Radiation Safety, Working with high
pressure water systems, Hand Signal Communication, Construction Safety (OSHA
500) and or General Industry Safety (OSHA 501)

21
 ISECTION 8: HEALTH AND SAFETY PLAN REQUIRED ELEMENTS I
Emergency response planning for a site needs to assure adequate coverage for
hazards described in the TSDS. Having as many workers as possible trained in CPR
and first aid is recommended.

I EvaluGion of personnels general health with emphasis on the cardiovascular and

respiratory system, back, and peripheral nervous system. Annual audiograms. I
1Workers must be trained in specific operation of equipment before use. I

SECTION 9: COMMENTS AND SPECIAL CONSIDERATIONS

Due to the high levels of noise produced, communication may become difficult.
Personnel working in the area should be familiar with and use hand signals as
necessary.

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

22
 HUMAN FACTORS INTERFACE

The technologies being tested for<concretedecontamination and decommissioning are

targeted for alpha contaminated concrete, therefore, the equipment operator was
dressed out in Anti-C (alpha radiation) PPE which included cloth suit, hood, inner and
outer boots, inner and outer gloves, and full face air-purifying respirator while
performing maintenance activities on the pump and lance. The only difficulty the
operator had while conducting maintenance on the equipment when wearing Anti-C
PPE was some visibility problems due to the full face respirator and a decrease in
tactile sensation in the hands and fingers. In addition, the need to perform work in the
Anti-C PPE caused some increase in heat stress for the operator.

The lance operator was dressed out in Saranex coated Tyvek with a hood, hard hat,
inner and outer gloves, and steel toed rubber work boots, and full face respirator during
operation. Problems encountered included decreased visibility due to the full face
respirator and an increase in heat stress. As would be expected, heat stress was a
greater problem in a Saranex coated suit than in the Anti-C ensemble. The operator
was then dressed out in a splash suit, inner and outer gloves, steel toed rubber work
boots, hard hat, safety glasses, and face shield. Again the main problem during
operation was decreased visibility, this time due to the face shield becoming fogged
and sprayed with water and contaminant. There was also an increase in heat stress '

again greater than in the Anti-C ensemble.

If the concrete being decontaminated had contamination other than or in addition to

alpha radiation, additional levels of protection, such as level A or level B PPE, may be
@
required for the operator. These may create additional human interface problems such
as a greater decrease in visibility and manual dexterity, an increase in heat stress, and
an overall increase in physical stress. It is recommended that additional safety and
health evaluations be conducted utilizing these higher levels of protection.

EMERGENCY RESPONSEIPREPAREDNESS

The ultra high pressure waterjet system would not be applicable for use in an
emergency response situation.

Before emergency response is initiated into an area where the ultra high pressure
waterjet is being used, complete shut down of the system needs to occur. Other
hazards associated with the location of its use at a hazardous waste clean up site need
to be considered. This might include alpha radiation, explosive atmospheres, or
unknown contaminants. All appropriate monitoring and routine precautions for a
I
hazardous waste site need to be taken into consideration.

23
Emergency response/preparedness planning and training for a site would need to take
into consideration not only routine emergencies that could be associated with an
worksite but special consideration needs to be given to credible emergencies that could
be encountered due to the high pressure water, diesel engine, and compressed air.
Foreseeable injuries from the high pressure water jet could include severe lacerations
and amputations.

If the Huskym has been used indoors, monitoring for O2before entry would be an
essential function.

SECTION 4
TECHNOLOGY APPLICABILITY

Upon observation the technology did not produce any visible dust in the atmosphe 3
and air monitoring did not show a significant dust level, as anticipated, due to the wet
environment associated with this technology. The waterjet did however, create a
situation where grit (small pieces of blasted concrete) was sprayed up to fifty feet from
the point where the waterjet was in contact with the concrete. The water spray and the
spray of concrete created a spread of contaminant that was evident on other surfaces
and the PPE of the operator. The flying pieces of concrete presented a severe eye
hazard. A splash suit or a water resistant Anti-C suit would not provide enough
protection against puncture from flying debris. A Saranex coated Tyvek or a level B
PVC suit may be required. In addition, safety glasses may not be protective enough
and goggles need to be worn under the face shield.

After the water dries the debris that has been spread by the water spray can become a
dust covering on the surface which if disturbed (especially in an enclosed environment)
could become an airborne contaminant and therefore, an inhalation hazard.

The water lance would not be difficult to decontaminate and the hoses would be and
could be considered consumables at the completion of the project. The HuskyTMwas
designed to operate outside of the contaminated environment and would be difficult to
decontaminate if circumstances required it be in the exclusion zone. The HuskyTM
would need to be torn down to decontaminate and this will not necessarily guarantee
that decontamination for alpha will be complete and it will be difficult to survey for alpha
contamination due to all of the small hard to reach (with a probe) spaces inherent in the
equipment.

24
 SECTION 5
REGULATORY/POLICY ISSUES

The site safety and health personnel where the ultra high pressure waterjet technology
is being used need to be concerned with safety and health regulations applicable to the
issues discussed above. Regulations that apply may be divided into four categories.
Core requirements are those regulations that would apply to any hazardous waste work
site, regardless of the type of job. Technology specific requirements are those
regulations that apply due to the specific technology being used. Special requirements
are standards and policies that are specific to the technology itself and are required by
reference in a regulation. Best management practices are not required but are
recommended by organizations such as the American National Standards Institute
(ANSI), the National Institute of Occupational Health and Safety (NIOSH), Department
of Energy (DOE), National Fire Protection Association (NFPA), etc. These
regulations/standards may include but not be limited to the following:

Core requirements:

4 OSHA 29 CFR 1926.25 Housekeeping

4 OSHA 29 CFR 1910.141 Sanitation (1910.141(a)(3) covers housekeeping)

4 OSHA 29 CFR 1926.53 Ionizing Radiation

@ 4 OSHA 29 CFR 1910.96 Ionizing Radiation

4 OSHA 29 CFR 1926 Subpart Z Toxic and Hazardous Substances

4 OSHA 29 CFR 1910 Subpart Z Toxic and Hazardous Substances

4 OSHA 29 CFR 1926.59 Hazard Communication

4 OSHA 29 CFR 1910.1200 Hazard Communication

4 OSHA 29 CFR 1926.64 Process Safety Management of Highly Hazardous

Chemicals

OSHA 29 CFR 1910.1 19 Process Safety Management of Highly Hazardous

Chemicals

OSHA 29 CFR 1926.65 Hazardous Waste Operations and Emergency

Response

25
+ OSHA 29 CFR 1910.120 Hazardous Waste Operations and Emergency
Response

+ OSHA 29 CFR 1926.23 First Aid and Medical Attention

+ OSHA 29 CFR 1910.151 Medical Services and First Aid

+ Occupational Safety and Health Act 1970(5)(a)(l) General Duty Clause

Technology specific requirements:

+ OSHA 29 CFR 1926 Subpart K Electrical

+ OSHA 29 CFR 1910 Subpart S Electrical

+ OSHA 29 CFR 1910 Subpart 0 Machinery and Machine Guarding

OSHA 29 CFR 1910.147 The Control of Hazardous Energy (LockoutTTagout)

OSHA 29 CFR 1926.52 Occupational Noise Exposure

+ OSHA 29 CFR 1910.95 Occupational Noise Exposure

+ OSHA 29 CFR 1926.103 Respiratory Protection

OSHA 29 CFR 1910.134 Respiratory Protection

OSHA 29 CFR 1926.102 Eye and Face Protection

OSHA 29 CFR 1910.133 Eye and Face Protection

OSHA 29 CFR 1926.28 Personal Protective Equipment

OSHA 29 CFR 1910.1 32 General Requirements (Personal Protective

Equ ipment)

+ ACGIH Threshold Limit Values for Chemical Substances and Physical Agents
and Biological Exposure Indices

26
 I
!

Best Management Practices:

+ ANSI S3.34-I986 Guide for the Measurement and Evaluation of Human

Exposure to Vibration Transmitted to the Hand

+ ANSI S3.18-I 979 Guide for the Evaluation of Human Exposure to Whole-body
Vibration

In addition to the above regulations and policies, it is imperative that all workers have
appropriate and adequate training for the task and associated safety and health
conditions. Training that would be required may be divided into four categories. Core
,
training is that which is required for anyone entering a hazardous waste site to perform
work, regardless of the type of job. Technology specific training is that training that is
specific to the technology and required by safety 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 not necessarily required by safety and health standards. Best
management practices are trainings that while not mandated by health and safety
standards, provide information and knowledge to the worker that will allow the worker to
perform hidher job safely. Training to be applied for the ultra-high pressure waterjet
may include but not be limited to:

Core training requirements:

+ HAZWOPER (Hazardous Waste Operations and Emergency Response)

+ HAZCOM (Hazard Communication)

+ Radiation Safety (Radiation Worker Training) for radiation sites

i

Technology Specific Training:

+ Respiratory Protection

+ Hearing Conservation

+ Personal Protective Equipment

+ Electrical Safety

+ Lockoutrragout

27
Special training:

+ Job specific training for equipment operation

Best Management Practice training:

Ergonomics (proper lifting, bending, stooping, kneeling, arm-hand vibration,

whole-body vibration

Heat stress (learning to recognize signs and symptoms)

Working with and around high pressure water systems

CPR/First Aid/Emergency Response/Bloodborne Pathogens

Hand Signal Communication

Construction Safety (OSHA 500) and or General Industry Safety (OSHA 501)

SECTION 6
OPERATIONAL CONSIDERATIONS & RECOMMENDATIONS

Recommendations made here for improved worker safety and health take into
consideration the operation of the HuskyTMand the waterjet lance. Specific
recommendations include:

+ It needs to be assured that workers are aware of the tripping hazards associated
with the hoses that are necessary to operate the equipment. In addition keeping
these as orderly as possible in compliance with good housekeeping regulations
will help avoid injury due to tripping.

+ The operators of the equipment need to have training in ergonomics to assure

proper techniques in lifting, bending, stooping, twisting, etc. during equipment
operation. The waterjet lance presented the most ergonomic problems due to the
stooped position the operator had to assume during operation in spite of using
the longest wand available. The weight of the lance was of concern due to its
ability to increase upper body/arm fatigue. The lance design needs to be
evaluated for the length and weight. Mounting the lance on a frame that would
allow for remote operation would reduce several of the ergonomic problems
associated with its use.

28
! + The waterjet operator was subjected to arm-hand vibration while operating the
equipment. The support handle on the lance was constructed of a hard rubber
material. This placed increased stress on the hand. A softer material would
place less pressure on the hand. The trigger on the lance for the waterjet was
made of metal and was designed for single finger operation. This will put stress
I on the index finger and could lead to problems such as trigger finger. A trigger
, design that uses several fingers and a soft material over the metal would be a
better choice.

+ The Huskym pump operator was subjected to whole-body vibration in part due to
the type of platform on which it was located. The platform on which the pump
will be located during a job needs to be considered for this. The platform and the
pump also need to be evaluated for anti-vibration engineering controls.

+ The HuskyTMpump did not require the operator to be with it at all times to
continue running. The operator was able to walk away from the pump and then
periodically check the gauges and operating conditions. This could lead to more
hazardous conditions for the lance operator. If a situation occurs where the
pump needs to be shut down immediately, the pump operator would not be able
to quickly hit the emergency stop button. The pump operator needs to stay with
the equipment at all times when the lance is in operation.

+ During the testing demonstration the HuskyTMpump was located on an elevated

platform (truck bed) which did not have side rails. Anytime the pump is located
on an elevated platform, there is the potential for a fall to below hazard. The
platform needs to have side rails and any ladders leading to the platform need to
have hand rails to allow three points of contact to be maintained while climbing.

+ The waterjet sprayed grit (small pieces of blasted concrete) and water up to fifty
feet away. This not only has the potential to spread contaminant but the flying
pieces present an eye and general struck by hazard. The operator may need
PPE that provides further protection than that afforded by Anti-C. A Saranex
coated Tyvek or level B PVC suit may be needed and goggles instead of safety
glasses.

+ The concrete debris and water that were sprayed during operations caused the
concrete surface and adjoining concrete surfaces to become slippery. This
could lead to a bad fall with severe injuries. Workers must be aware of this
hazard and avoid it by walking around these areas when possible.

+ The spray may also cause contamination to be spread along with the water and
debris. This will need to be evaluated on a case by case, job by job basis.

29
 Noise exposure was significant during operation of the technology. Since testing
was done in an outdoor environment, it is plausible that the noise levels would
increase in an enclosed environment. The equipment needs to be evaluated for
possible engineering controls to help decrease the noise exposure to the
operator. If engineering controls are not possible, administrative controls, and/or
adequate hearing protection must be incorporated during operation.

Due to the windy outdoor environment in which the testing demonstration was
conducted and therefore, the noise monitoring was conducted, it is recommended that
further testing for noise exposure be conducted while the technology is used in an
enclosed environment similar to environments in which it would be used at a hazardous
waste clean-up site. This would also allow for a more thorough evaluation of the heat
stress to be encountered while wearing the appropriate PPE.

It is also recommended that the operation and maintenance activities be evaluated

while the operator is wearing level A and level B PPE since these levels may be
needed in environments where the concrete contamination is mixed in nature or other
than radiation.

The safety and health issues discussed throughout this report could be reduced and in
some cases eliminated if this type of high pressure water jet technology could be
designed to operate remotely.

30
 APPENDIX A
REFERENCES

Occupational Safety and Health Standards for General Industry, 29 CFR Part I 9 10,
Occupational Safety and Health Administration United States Department of Labor,
1995

Occupational Safety and Health Standards for the Construction Industry, 29 CFR Part
1926, Occupational Safety and Health Administration United States Department of
Labor, 1995

Threshold Limit Values (TLVs) for Chemical Substances and Physical Agents and
Biological Exposure Indices (BEls), American Conference of Governmental Industrial
Hygienists, 1995-1996

ANSI 1986, Guide for the measurement and evaluation of human exposure to vibration
transmitted to the hand, New York, NY: American National Standards Institute, ANSI
s3.34

31
 APPENDIX 6
IH SAMPLING DATA

5/20/96 052096-Flu-016 Total dust 2.0000 mg/m3

5/20/96 052096-Flu-017 Total dust 0.0000 mg/m3
5/20/96 052096-Flu-018 Blank 0.0000 mg/m3
5/20/96 052096-Flu-020 Total dust 84.103mg/m3
I5/20/96 I 052096-Flu-021 I Total dust I 0.2540 mg/m3
* The OSHA PEL for total dust is 15 mg/m3and the ACGlH TLV is 10 mg/m3.
Current sampling was conducted for total dust. The need to sample for
respirable dust and silica has to be considered during concrete decontamination
and decommissioning activities.

.-
32
 NOISE SAMPLING

dBCI
< 8 5 . 8 d B : 28.301% 85 8 + 8 5 . 9 d B : 1 169% Ln (78.538 > = 8 5 . 9 d B

The above graph shows the distribution of noise for the Huskym pump operator. The
percentage of time spent at each decibel level can be obtained from the graph. As
shown, 28.301% of the time the noise exposure was less than 85 dBA which means
that the majority of the time or 71.699% of the time the noise exposure was at sound
levels above 85 dBA. OSHA requires that a hearing conservation program be initiated
if the 8-hour TWA is 85 dBA.

33
 NOISE SAMPLING

12

8
4
C
PI
P
L 6
PI
R

0
.e
dBt9
<8S.edB: 21.637% 85.8+85.9dB : 0.842%

The above graph shows the distribution of noise for the waterjet lance operator. The
percentage of time spent at each decibel level can be obtained from the graph. As
shown, 21.637% of the time the noise exposure was less than 85 dBA which means
that the majority of the time or 78.363% of the time the noise exposure was at sound
levels above 85 dBA. OSHA requires that a hearing conservation program be initiated.

34
 M98002045
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