Evaluation of an improved prototype mini-baghouse to control the release of respirable crystalline silica from sand movers.

The OSHA final rule on respirable crystalline silica (RCS) will require hydraulic fracturing companies to implement engineering controls to limit workers' exposure to RCS. RCS is generated by pneumatic transfer of quartz-containing sand during hydraulic fracturing operations. Chronic inhalation of RCS can lead to serious disease, including silicosis and lung cancer. NIOSH research identified at least seven sources where RCS aerosols were generated at hydraulic fracturing sites. NIOSH researchers developed an engineering control to address one of the largest sources of RCS aerosol generation, RCS escaping from thief hatches on the top of sand movers. The control, the NIOSH Mini-Baghouse Retrofit Assembly (NMBRA), mounts on the thief hatches. Unlike most commercially available engineering controls, the NMBRA has no moving parts and requires no power source. This article details the results of an evaluation of generation 3 of the NMBRA at a sand mine in Arkansas from May 19-21, 2015. During the evaluation, 168 area air samples were collected at 12 locations on and around a sand mover with and without the NMBRA installed. Analytical results for respirable dust and RCS indicated the use of the NMBRA effectively reduced concentrations of both respirable dust and RCS downwind of the thief hatches. Reductions of airborne respirable dust were estimated at 99+%; reductions in airborne RCS ranged from 98-99%. Analysis of bulk samples of the dust showed the likely presence of freshly fractured quartz, a particularly hazardous form of RCS. Use of an improved filter fabric and a larger area of filter cloth led to substantial improvements in filtration and pressures during these trials, as compared to the generation 2 NMBRA. Planned future design enhancements, including a weather cover, will increase the performance and durability of the NMBRA. Future trials are planned to evaluate the long-term operability of the technology.

The Generation Rate of Respirable Dust from Cutting Fiber Cement Siding Using Different Tools.

This article describes the evaluation of the generation rate of respirable dust (GAPS, defined as the mass of respirable dust generated per unit linear length cut) from cutting fiber cement siding using different tools in a laboratory testing system. We used an aerodynamic particle sizer spectrometer (APS) to continuously monitor the real-time size distributions of the dust throughout cutting tests when using a variety of tools, and calculated the generation rate of respirable dust for each testing condition using the size distribution data. The test result verifies that power shears provided an almost dust-free operation with a GAPS of 0.006 g m-1 at the testing condition. For the same power saws, the cuts using saw blades with more teeth generated more respirable dusts. Using the same blade for all four miter saws tested in this study, a positive linear correlation was found between the saws' blade rotating speed and its dust generation rate. In addition, a circular saw running at the highest blade rotating speed of 9068 rpm generated the greatest amount of dust. All the miter saws generated less dust in the 'chopping mode' than in the 'chopping and sliding' mode. For the tested saws, GAPS consistently decreased with the increases of the saw cutting feed rate and the number of board in the stack. All the test results point out that fewer cutting interactions between the saw blade's teeth and the siding board for a unit linear length of cut tend to result in a lower generation rate of respirable dust. These results may help guide optimal operation in practice and future tool development aimed at minimizing dust generation while producing a satisfactory cut.

The development and testing of a prototype mini-baghouse to control the release of respirable crystalline silica from sand movers.

Inhalation of respirable crystalline silica (RCS) is a significant risk to worker health during well completions operations (which include hydraulic fracturing) at conventional and unconventional oil and gas extraction sites. RCS is generated by pneumatic transfer of quartz-containing sand during hydraulic fracturing operations. National Institute for Occupational Safety and Health (NIOSH) researchers identified concentrations of RCS at hydraulic fracturing sites that exceed 10 times the Occupational Safety and Health Administration (OSHA) Permissible Exposure Limit (PEL) and up to 50 times the NIOSH Recommended Exposure Limit (REL). NIOSH research identified at least seven point sources of dust release at contemporary oil and gas extraction sites where RCS aerosols were generated. NIOSH researchers recommend the use of engineering controls wherever they can be implemented to limit the RCS released. A control developed to address one of the largest sources of RCS aerosol generation is the NIOSH mini-baghouse assembly, mounted on the thief hatches on top of the sand mover. This article details the results of a trial of the NIOSH mini-baghouse at a sand mine in Arkansas from November 18-21, 2013. During the trial, area air samples were collected at 12 locations on and around a sand mover with and without the mini-baghouse control installed. Analytical results for respirable dust and RCS indicate the use of the mini-baghouse effectively reduced both respirable dust and RCS downwind of the thief hatches. Reduction of airborne respirable dust ranged from 85-98%; reductions in airborne RCS ranged from 79-99%. A bulk sample of dust collected by the baghouse assembly showed the likely presence of freshly fractured quartz, a particularly hazardous form of RCS. Planned future design enhancements will increase the performance and durability of the mini-baghouse, including an improved bag clamp mechanism and upgraded filter fabric with a modified air-to-cloth ratio. Future trials are planned to determine additional respirable dust and RCS concentration reductions achieved through these design changes.

On the Characterization of the Generation Rate and Size-Dependent Crystalline Silica Content of the Dust from Cutting Fiber Cement Siding.

A laboratory testing system was developed to systematically characterize the dust generation rate and size-dependent crystalline silica content when cutting or shaping silica containing materials. The tests of cutting fiber cement siding in this system verify that it provides high test repeatability, making it suitable for the targeted characterizations. The mass-based size distributions obtained from a gravimetric-based instrument and a direct reading instrument both show bimodal lognormal distributions with a larger mode ~13 µm and another mode <5 µm for the dusts from cutting four different brands of fiber cement siding. The generation rates of respirable dust obtained from the two instruments are comparable, and the results from each instrument are similar for the four brands. The silica content in the airborne dusts, however, strongly depends on the amount of silica used in the respective product. It is also observed that the silica content in the airborne dust from cutting the four brands of fiber cement siding showed the same trend of an increase with the aerodynamic diameter of the dust, approaching the silica content levels found in their respective bulk samples. Combining the results for both the dust size distribution and size-dependent silica content, it is found that most of the respirable crystalline silica (RCS) resides in the dust ~2.5 µm in aerodynamic diameter. These results would help guide the development of specific engineering control measures targeted at lowering workers' exposure to RCS while cutting fiber cement siding. With the high repeatability using the laboratory testing system, the dust generation rate could then be characterized under different operating conditions, and with the deployment of various engineering control measures. This would greatly facilitate the systematic evaluation of the control effectiveness and the selection of the optimal control solutions for field trials.

Short-term monitoring of formaldehyde: comparison of two direct-reading instruments to a laboratory-based method.

Airborne formaldehyde concentrations can be measured using several different techniques, including laboratory-based methods and direct-reading instruments. Two commercially available direct-reading instruments, an RKI Instruments Model FP-30 and a PPM Technology Formaldemeter htV, were compared with National Institute for Occupational Safety and Health Method 2016 in different test environments to determine if these direct-reading instruments can provide comparable results. The methods yielded the following mean concentrations for 47 samples: NIOSH Method 2016, 0.37 ppm; FP-30, 0.29 ppm; and htV, 0.34 ppm. Results from both of the direct-reading instruments were correlated with the laboratory-based method (R² = 0.78 for FP-30, and 0.902 for htV). Comparison of the means of the three methods showed that on average the FP-30 instrument (p < 0.001) differed statistically from NIOSH Method 2016, whereas the htV (p = 0.15) was not statistically different from the NIOSH method. Sensitivity and specificity tests demonstrated that the FP-30 had sensitivity above 60% to detect formaldehyde concentrations at all the cutoff levels tested, whereas the htV appeared to have greater sensitivity above 88% for the levels evaluated.

Laser in situ keratomileusis flap tear during lifting for enhancement in the presence of post-photorefractive keratectomy corneal haze.

A patient who had photorefractive keratectomy for low myopia 6 years earlier had an enhancement by hyperopic laser in situ keratomileusis (LASIK). Moderate reticular corneal haze developed after LASIK. An attempted flap lift 4 months after LASIK resulted in a flap tear at the edge of the zone of corneal haze. Because haze can indicate an area of exuberant wound healing that can result in flap adhesion to the bed, recutting a LASIK flap may be safer than lifting it in the presence of haze.