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Building Number/Name: |
333 |
PAST OPERATIONS
Location(s) in facility that contained beryllium materials: Braze rings (which contained approximately 5% beryllium) for N-Reactor fuel were cut, brazed, welded, wire brushed, heat treated, lathed, and vacu-blasted in many portions of this facility, which was built for this purpose. Specific areas with known routine beryllium work include the End Cap Brazing area, Step Cut area, End Weld area, and the Beryllium Maintenance Room, where beryllium-contaminated equipment (such as vacuum pumps) was overhauled. Beryllium was also present in the Chem Bay Area in the past.
Description of beryllium activities: This building, known as the Fuels Manufacturing building, was constructed in 1960 to manufacture fuels for the N-Reactor. The fuel itself was a uranium/zirconium combination that was extruded into long fuel rods, then cut to the proper length. The ends of each length were then milled and the braze rings inserted and melted. The fuel was then heat-treated, acid-cleaned, machined, and welded or worked as necessary to pass inspection qualifications. Local ventilation was generally used for all operations where generation of beryllium dust or fumes was possible.
Building monitoring data summary: When beryllium operations were first piloted in 1961, samples were obtained to assist in the development of appropriate beryllium controls. Numerous additional air and swipe samples were obtained from 1961 through 1988. A 1968 report noted that an exhaust ventilation system was installed at the power wire end brush in August 1968. Power wire brushing was conducted in the end weld area of the facility. Five air samples were collected before installation of the new system, with reported results of 0.9 mg/m3 (breathing zone - normal operation), 29.0 mg/m3 (breathing zone - extra pressure exerted), 1.8 mg/m3 (air under Lucite shield), 0.4 mg/m3 (breathing zone - brushing with electric drill), and 19.2 mg/m3 (3 inches above wire brush). These samples were intended to estimate historical conditions at this station. Two breathing zone samples were collected after installation of the system with results of 0.17 mg/m3 (normal operations) and 0.66 mg/m3 (extra pressure exerted). A routine monitoring program was established in early 1970, with monthly monitoring completed for all facility beryllium operations. According to the monitoring results, air concentrations were generally maintained below DOE limits of 2.0 mg/m3 . However, many air samples had monitoring results that were at or greater than 0.1 mg/m3. Air samples identified above 0.2 mg/m3 after this program was initiated include 0.85 mg/m3 (mid-end welder - March 1975), 0.27 mg/m3 (breathing zone at north end welder - Feb 1980), 0.51 mg/m3 (Vacublast - Dec 1980), 0.25 mg/m3 (Vacublast - Aug 1983), 0.38 mg/m3 (Braze Room - Aug 1983), and 0.30 mg/m3 (Braze Room - Sept 1983). Significant to high levels of airborne beryllium were additionally identified during routine monitoring in January/February 1987. Reported concentrations included 1.76 mg/m3 (Autoblast #2), 2.45 mg/m3 (end-weld #1), 1.113 mg/m3 (Braze Room), 3.566 mg/m3 (Auto blast #1), and 0.28 mg/m3 (Grinding Area #2). However, subsequent review of this data in 1987 indicated that the results were in error from an undetermined source of contamination in the laboratory. In 1971, a major effort was initiated to minimize beryllium surface contamination levels in all areas. A beryllium permit system was also used to document the controls and personnel involved with activities in these beryllium areas. In July and August of 1988, 69 samples were taken with 35 slightly exceeding the public release levels of 0.01 mg/in2 (or approximately 0.16 mg/100 cm2). Areas above the limit were cleaned and reanalyzed prior to release.
Personnel monitoring data summary: All personnel who were routinely exposed to beryllium operations and/or maintenance were enrolled in a beryllium monitoring and medical surveillance program. Personnel monitoring was conducted on 3 employees in July 1975, 3 in December 1975, 3 in January 1976, 3 in February 1976, 1 in January 1979, 1 in June 1980, 1 in July 1980, 1 in September 1980, and 1 in August 1984. For all of these employees, results ranged from 0.120 to 0.620 mg/m3.
Specify Engineering/Administrative controls used during operations: Ventilation was in place for all beryllium operations and normal skin coverings (gloves, coveralls, etc.) were used.
Maximum Estimated Past Be exposure: HIGH prior to 1972, SIGNIFICANT after 1972
CURRENT OPERATIONS
Building still present: YES
Beryllium present: YES (trace amounts)
Current building occupancy/activity: Operations in this facility ceased in 1987 and the building is in transition for turnover for decommissioning. The extrusion press located in the south half of the building will be removed from the building and used by a private commercial industry.
1999 Study Results: Four ambient air samples were collected in 333 from the following locations: 1) just outside the second floor men’s room ( 6/14/99); 2) immediately outside the Maintenace Room door; 3) in the East Mezzanine on top of furnace panel "EB" (6/23/99); and 4) near the east wall of the Stepcut Area A016 (7/7/99). Personal air samples were collected in the breathing zones of technicians while wipe sampling surfaces on the first floor (6/14/99), second floor mezzanines (6/15/99), Chem Bay (6/17/99), and outside the Maintenance Repair Room (6/23/99) for beryllium. Results reported for the air samples were below the Method Detection Limit (MDL) of 0.004 and 0.013 µg/m3 for the ambient and personal samples, respectively. Of the 103 wipe samples collected throughout the building, 14 samples had beryllium concentrations above the MDL of 0.5 mg/100 cm2. Three of these samples were in the End Cap Braze area (1.4, 10, 11 mg Be/100 cm2), six were in the Stepcut area (0.61, 5.2, 6.4, 3.6, 1.2, 1.3 mg Be/100 cm2), two were in the End Weld area (4.6, 1.2 mg Be/100 cm2), and three were just outside the Maintenance Room (1.3, 0.74, 7.4 mg Be/100 cm2). Results reported from all other surface samples taken in 333 were below the MDL. Areas that were unable to be sampled but should be considered as potentially contaminated with beryllium include: the interior of the Maintenance Room; the interiors of all machinery and storage cabinets in the End Braze, End Weld, and Step Cut areas, the Chem Bay, the Beryllium Maintenance Room, and adjacent areas, and the local and general exhaust systems serving these areas.
Sampling Results Following the 1999 Study: Sampling/Monitoring for beryllium in the 333 Facility will continue in support of work packages over and above routine surveillance provided and as appropriate. Sampling since the 1999 Study, has included 73 Surface Wipe samples, 18 Ambient Air samples, and 17 Breathing Zone samples. All were found to be below the MDL (Minimum Detection Level) of .5 mg Be/100 cm2, 0.008 µg/m3, and 0.004µg/m3 for wipe, breathing zone, and ambient air respectively. Note: Additional samples have not been collected in the 4 areas noted as contaminated in the 1999 study, but these areas will be sampled further as work progresses in these areas.
2002-2003: Numerous surface wipe samples have been taken, and breathing zone monitoring has been conducted. Out of 71 wipe samples taken, all but 6 have been <0.2 ug/100 cm2. The six that were >.2 limit of detection were taken in very dirty areas with substantial accumulations of dirt. Four of these were taken from on top of the beryllium duct, and two were taken in the CA, where clean-up was being planned. In addition, monitoring in the breathing zone for 6 employees have resulted in levels < detectable at 0.005 ug/m3.
Operational Controls: Work activities are planned and reviewed with consideration given to the potential for beryllium exposure, and often sampling will be conducted before and/or during the work evolution. Controls are prescribed when the work activity may potentially enter or disturb an area not yet characterized through beryllium sampling/monitoring. Based on beryllium sampling performed and historical knowledge of presence in the facilities in particular areas, special precautions and controls will continue in these areas, and areas not yet sampled, but where there is still a potential of beryllium exposure. Non-routine work, work in the 4 identified areas of known contamination, and work in areas not characterized, is carefully planned with IH/IS professional support to help assure potential exposure risks are minimized and characterized through the use of appropriate controls and additional sampling as determined by I.H.
Maximum Estimated Current Be Exposure from Routine Activities: SLIGHT
Basis for above information: Stone and Webster report, publication WHC-MR-0388, and personnel interviews; FDH beryllium assessment report.
Comments, including any additional information needed (specify): Beryllium may still exist at low levels in the maintenance repair room and ventilation ducting . The maintenance repair room has been closed for 15 years, but there are several holes, vents, and ducts in the walls that allow air exchange between the interior and exterior of the room. Disturbance of any beryllium inside could lead to deposition of beryllium dust in the area surrounding the maintenance repair room. As for the former machining equipment, numerous smear samples were obtained in 1988 prior to the equipment being released to the public. In July and August of 1988, 69 samples were taken, with 35 slightly exceeding the public release level of 0.01 mg/in2. Areas above the limit were cleaned and reanalyzed prior to release.
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