Monitoring personnel exposure to stainless steel welding fumes in confined spaces at a petrochemical plant.

This paper documents exposure to stainless steel welding fumes at a petrochemical plant. The situation evaluated may be separated into three categories: 1) evaluation of background concentration levels in a maintenance shop (area monitoring), 2) evaluation of personnel exposures during open air welding in a maintenance shop (personal monitoring), 3) evaluation of personnel exposures in confined space welding (personal monitoring). Thirty-five area samples and seventy-six personal samples were collected and analyzed for chromium (VI), total chromium, nickel, iron, copper, and total particulates. The background concentrations in the maintenance shop were found to be far below those felt to be harmful. Personnel exposures found in the maintenance shop during open air welding were also low, especially when compared to current OSHA permissible exposure levels. Contaminant levels found during confined space welding, as in distillation towers, were considered excessive. After several possible solutions to the problem were considered, it was decided to implement a mandatory air-line respirator program for all employees entering confined spaces during stainless steel welding operations.