71

APPENDIX B

PRINCIPAL HAZARDOUS ACTIVITY

EVALUATION SUMMARY

Table B-1outlines the principal hazardous activities

conducted at PGDP between 1952 and 1990. This

table provides an assessment of the hazards

encountered by these activities, the controls used to

mitigate the hazards, and the effectiveness of the

controls. Acronyms are defined at the end of the table.

Description

Ash handling (or

hot hauling)

Baghouse filter

cleaning and

changes

Building access

Burial of

pyrophoric

uranium metal in

landfills

Carpentry

Crane operation

Cylinder heel

cleaning

Deblading of

compressor

rotor and stator

Plant

Location

C-410,

C-746B,

C-400

All

C-340

C-749

Cooling

Towers

C-400, C-410

C-420, C-331

C-33, C-335

C-337, C-340

C-400

C-400

Hazards

RAD, exposure to

UF6

 gas, and

inhalation of dust

containing uranium

and concentrated

daughter products,

fission products,

and transuranics

Airborne UF4

,

Uranium oxides,

process dust, RAD

Green salt, black

oxides on floors

and other surfaces

Exposure to

uranium metal

Asbestos, arsenic,

fungicides

Process gas, heat

stress

RAD, exposure to

UF6

 gas, and

inhalation of

concentrated

daughter products,

fission products,

and transuranics

Possible release

of UF6

, HF, UO2F2,

transuranics and

uranium daughters

to shop area

Controls

PPE, worker rotation,

film badges or TLD,

stay times, bioassay

program, ambient air

flow

PPE, film badges or

TLD, stay times,

bioassay program,

ambient air flow

PPE, housekeeping

None

PPE

PPE

PPE, film badges or

TLD, stay times,

bioassay program,

ambient air flow

UF6

 negative

procedure, washing,

and PPE

Effectiveness

Moderately

effective when

used correctly

Moderately

effective when

used correctly

Ineffective

Ineffective

Effective when

used correctly

Effective when

used correctly

Moderately

effective when

used correctly

Moderately

effective when

used correctly

Time

 Period

1952-1964,

1968-1976

1950s-1990

1957-1977

1952-1980s

1952-1990

1952-1990

1952-1990

1975-1981,

During CIP/

CUP

Table B-1. Paducah Gaseous Diffusion Plant Principal Hazardous Activity Evaluation Summary: 1952-1990
72

Description

Derby breakout,

roasting,

cleaning, and

sawing

Disassembly of

stuck shut G-17

cell block valves

Drum crushing

Drumming

green salt

Dumping

uranium from

vacuum

collector to

drums and

returning

uranium to

process

Electrical

Fabrication

Firing reduction

vessels (bombs)

to make derbies

Flange grinding

Plant

Location

C-340

C-720

C-746

C-340

C-410, C-420

All

C-720

C-340

C-400, C-340,

C-410, C-420

Hazards

Uranium metal,

black oxides of

uranium, unburned

Mg, uranium

bearing sludge

from quench tank

Possible release

of UF6

, HF, UO2F2,

transuranics, and

uranium daughters

to shop area

RAD, UF4, and

inhalation of

uranium dust

Green salt dust

RAD and

inhalation of

uranium dust

Process gas,

PCBs, solvents,

U3

O8, lead

Lead, solvents

Vessel exploded in

1962 due to Mg

overload; lid fires,

burnouts could

release molten

uranium

U3O8 (yellowcake),

HF

Controls

PPE, use of downdraft

table for cleaning;

later modified for

improved ventilation

flow and control of

dust, fire

extinguishers;

operators on

urinalysis

PPE, UF6

 negative

procedure,

disassembly

procedure, shop

evacuation

PPE

PPE required in 1/8/

57 when drumming

PPE, bioassay

program, ambient air

flow

PPE

PPE

Fire protection

system, design of

bomb, specifications

on mandrels for

producing bomb

liners, operators on

urinalysis

PPE

Effectiveness

Effectiveness

could not be

determined;

operators may not

have been properly

monitored for lung

burden of insoluble

oxides

Moderately

effective when

used correctly

Respiratory

protection was not

used until Health

Physics and

Hygiene identified

serious concerns

with airborne

radioactive

material

concentrations in

September 1981

Effective when

used correctly

Moderately

effective when

used correctly

Effective when

used correctly

Effective when

used correctly

Effective when

used correctly

Moderately

effective when

used correctly

Time

 Period

1957-1977

1952-1990

1980-1982

1957-1977

1952-1964,

1968-1976

1950s-1990

1950s-1990

1957-1962,

1968-1977

1950s-1990
73

Description

Groundskeeping

Guard patrolling

HF collection

and transfer to

C-410

Landfill

operations

Lubrication

Machining

Maintenance on

roof

Midnight

negatives

Mixing UF4

powder with Mg

powder, loading

into bomb

Neptunium

recovery

Plant

Location

All

All buildings

C-340

C-746 K, S &

T(inert)

All

C-720

C-340

C-331, C-333

C-335, C-337

C-340

C-400, C-710

Hazards

RAD, PCBs,

asbestos, arsenic,

fungicides

Airborne UF4

,

uranium oxides,

process dust,

RAD, TCE, HF,

process gas, lead

Anhydrous HF,

cryogenic fluids

Asbestos and ash

from coal fired

plant, dust from

contaminated

building rubble

PCBs, solvents,

process gas, U3O8

Lead, process gas,

solvents, uranium,

beryllium

Venting of HF and

uranium to roof

from reduction

towers

Release of UF6,

HF, UO2

F2,

transuranics, and

uranium daughters

to environment

Airborne UF4

powder, Mg metal

powder, dust

High

concentrations of

neptunium-237 in

process solution;

potential internal

dose from leaks

Controls

No PPE

PPE, film badge, or

TLD

Closed system for

collection and

condensation of HF

from towers; face

shield, rubber gloves,

apron, and hood; area

roped off and

impermeable suit used

when systems open

None; in early 1980s,

added controls on

asbestos and building

rubble disposal

PPE

PPE

None; roof access

controls implemented

in December 1973

Procedures limited

practice to only

purging cells with

<10 ppm UF6

PPE, film badge or

TLD, Building dust

collection system;

spark proof tools

provided for work in

the magnesium room;

operators on urinalysis

PPE

Effectiveness

Ineffective

Minimally

effective; PPE was

generally used only

during emergency

situations

Moderately

effective

Ineffective

Moderately

effective when

used correctly

Effective when

used correctly

Ineffective

Effective, but may

have been ignored

in some cases

Moderately

effective when

used correctly

Moderately

effective when

used correctly;

some air samples

high

Time

 Period

1952-1970s

1950s-1990

1957-1977

1950s-1980s

1950s-1990

1952-1990

1957-1977

Prior to April

1986

1957-1962,

1967-1977

1958 to mid1960s
74

Description

Product

withdrawal

during normal

operations

Pulverizer

operations and

maintenance

Release

response

Removal of

ì000î

compressor stub

shaft

Removal of

compressor

seals

Removal of

converter shell

internal fixtures

Replacement of

full UF6

 cylinder

valve

Slag recovery

Smelting

Plant

Location

C-310

C-400

Process and

support

buildings;

C-331, C-333

C-335, C-337

C-310, C-315

C-340, C-400

C-410, C-420

C-720

C-400, C-720

C-409

Outside

C-400

C-340 Slag

Plant

C-746

Hazards

RAD, exposure to

UF6 gas from

positive pressure

system leaks and

cylinder change-outs

RAD and inhalation

of dust containing

uranium and

concentrated

daughter products,

fission products,

thorium, and

transuranics;

including neptunium

and plutonium

Inhalation of

radioactive

materials/skin

contamination,

chemical burns

Possible release of

UF6

, HF, UO2F2,

transuranics, and

uranium daughters to

shop area

Possible release of

UF6, HF, UO2F2,

transuranics, and

uranium daughters to

shop area

Possible release of

UF6, HF, UO2F2,

transuranics, and

uranium daughters to

shop area

Possible release of

UF6, HF, UO2F2,

transuranics, and

uranium daughters on

repair team and into

environment

Uranium oxides and

MgF2

 dust

Airborne uranium,

transuranics, process

metals, RAD, HF,

process gas

Controls

PPE, worker rotation,

film badges or TLD,

stay times, bioassay

program, ambient air

flow

PPE, worker rotation,

film badges or TLD,

stay times, bioassay

program, ambient air

flow

PPE, ventilation

PPE, UF6

 negative

procedure, local area

exhaust, and pit and

shop evacuation

PPE, UF6 negative

procedure, and shop

evacuation

PPE, UF6 negative

procedure, additional

purge in cell and in

shop, shop evacuation

PPE, repair procedure,

cooling cylinder to

sub-atmospheric, and

emergency response

procedures

PPE, film badges

PPE, air samples, film

badges or TLD,

bioassay program

Effectiveness

Moderately

effective when

used correctly

Moderately

effective when

used correctly

Effective when

used correctly;

ventilation systems

were frequently

inoperable

Moderately

effective when

used correctly

Moderately

effective when

used correctly

Moderately

effective when

used correctly

Effective

Not typically noted

in operations

instructions

Moderately

effective when

used correctly

Time

 Period

1952-1990

1952-1964,

1968-1976

1952-1990

1952-1990

1952-1980s

1975ñ1981

During CIP/

CUP

1952-1990

1957-1977

1950s-1990
75

Description

Spraying

cooling towers

with fungicide

Technetium

recovery

UF6

 reduction to

UF4

Unplugging feed

plant transfer

lines, hoppers,

and conveyers

using sledge

hammers and

rods during

normal

operation

Unplugging

fluorination

towers

Uranium powder

conveyer,

hopper, and

other equipment

maintenance and

replacements

Uranium

recovery (by

solvent

extraction)

Welding

Plant

Location

Cooling

towers

C-400

C-340

ìPowderî

Room (5th

and 6th floors

of the tower)

C-410, C-420

C-410

C-410, C-420

C-400

C-410, C-411,

C-420, C-600,

C-720, and all

process

buildings

Hazards

Pentachlorophenol

High

concentrations of

technetium-99 in

process solutions;

potential skin and

internal dose from

leaks

UF6 leakage, UF4

leakage, HF

leakage, and

airborne uranium

RAD, inhalation of

uranium dust,

noise

RAD, exposure to

UF6

 gas, and

inhalation of dust

containing uranium

and concentrated

daughter products,

fission products,

and transuranics

RAD and

inhalation of

uranium dust

Concentration of

technetium-99;

transuranics and

uranium daughters

provided potential

radiation exposure

and radioactive

effluents

Heat stress, acids,

process gas,

asbestos, HF,

thermal burns

Controls

PPE, procedures, and

monitoring

PPE

PPE, film badge or

TLD, building dust

collection system,

operators on

urinalysis

PPE, bioassay

program, ambient air

flow

PPE, film badges or

TLD, stay times,

bioassay program,

ambient air flow

PPE, bioassay

program, ambient air

flow

Rubber gloves and

respirators available;

effluents were

sampled and release

limits were applied

PPE

Effectiveness

Moderately

effective when

used correctly

Moderately

effective when

used correctly; no

problems evident

in bioassay results

Moderately

effective when

used correctly

Moderately

effective when

used correctly

Moderately

effective when

used correctly

Moderately

effective when

used correctly

Moderately

effective when

used correctly;

little guidance or

directionon use of

respirators; PPE

worn at discretion

of operator

Effective when

used correctly

Time

 Period

1952-1990

1961-1963,

1970s

1957-1962,

1967-1977

1952-1964,

1968-1976

1952-1964,

1968-1976

1952-1964,

1968-1976

1950s to mid1970s

1950s-1980s
76

Key:

CIP Cascade Improvement Program

CUP Cascade Uprating Program

HF Hydrogen Fluoride

PCB Polychlorinated Biphenyl

PPE Personal Protective Equipment (includes

one or more of: respirator, shoes, ear plugs,

and anti-contamination clothing)

RAD Includes one or more of alpha, beta, or

gamma radiation

TCE Trichloroethene

TLD Thermoluminescent Dosimeter
Abbreviations Used in This Report

AEC Atomic Energy Commission

ACGIH American Conference of Governmental Industrial Hygienists

ALARA As Low As Reasonably Achievable

CERCLA Comprehensive Environmental Response, Compensation, and Liability Act

CIP/CUP Cascade Improvement Program/Cascade Uprating Program

CFR Code of Federal Regulations

DOE U.S. Department of Energy

EPA Environmental Protection Agency

ERDA Energy Research and Development Administration

ES&H Environment, Safety, and Health

HF Hydrogen fluoride or hydrofluoric acid

IVRML In Vivo Radiation Monitoring Laboratory

JHA Job Hazard Analysis

KOW Kentucky Ordnance Works

KPDES Kentucky Pollutant Discharge Elimination System

MAC Maximum Allowable Concentration

MPC Maximum Permissible Concentration

MTM Material Terminal Management

NPDES National Pollutant Discharge Elimination System

NRC Nuclear Regulatory Commission

OR Oak Ridge Operations Office

ORNL Oak Ridge National Laboratory

OSHA Occupational Safety and Health Administration

PCB Polychlorinated biphenyl

PCP Pentachlorophenol

PGDP Paducah Gaseous Diffusion Plant

PPE Personal Protective Equipment

ppm parts per million

PSO Paducah Site Office

RCRA Resource Conservation and Recovery Act

RCG Radiation Control Guide

SPP Standard Practice Procedure

SWMU Solid Waste Management Unit

TCE Trichloroethene

TLV Threshold Limit Value

TSCA Toxic Substances Control Act

USEC United States Enrichment Corporation