Recent achievements in the control of PAH exposure on coke oven ...

<strong>Recent</strong> <strong>achievements</strong> <strong>in</strong> <strong>the</strong> <strong>control</strong> <strong>of</strong> <strong>PAH</strong> <strong>exposure</strong>at Tata Steel’s UK coke oven plants.Presented at <strong>the</strong> Coke Oven Managers’ Association Conference on 29 th March 2012byT M Conroy, D Wilcox, D R Anderson & R FisherSummaryA paper presented to COMA at Scunthorpe on 13 th January 2011 [1] discussed progress on<strong>the</strong> reduction <strong>of</strong> coke oven workers <strong>exposure</strong> to polycyclic aromatic hydrocarbons (<strong>PAH</strong>s).Details were provided on <strong>the</strong> selection <strong>of</strong> a new generation <strong>of</strong> powered respirator and areview <strong>of</strong> <strong>the</strong> personal protective equipment (PPE) regime.This paper provides a comprehensive review <strong>of</strong> <strong>the</strong> effectiveness <strong>of</strong> <strong>the</strong>se and o<strong>the</strong>rimplemented measures such as <strong>the</strong> provision <strong>of</strong> awareness sessions at Tata Steel’s cokeoven plants <strong>in</strong> <strong>the</strong> UK. It details how <strong>the</strong> use <strong>of</strong> biological monitor<strong>in</strong>g has identified significantreductions <strong>in</strong> <strong>exposure</strong> follow<strong>in</strong>g implementation <strong>of</strong> <strong>control</strong>s to date. The importance <strong>of</strong>procedural and adm<strong>in</strong>istrative <strong>control</strong>s, such as <strong>the</strong> support<strong>in</strong>g <strong>of</strong> no smok<strong>in</strong>g and no eat<strong>in</strong>gpolicies <strong>in</strong> areas where carc<strong>in</strong>ogens are present, <strong>the</strong> use <strong>of</strong> job rotation, and <strong>the</strong> review <strong>of</strong>standard work<strong>in</strong>g practices, are highlighted to ensure <strong>the</strong> susta<strong>in</strong>ability <strong>of</strong> <strong>control</strong> measuresand compliance with legislation.The derivation and implementation <strong>of</strong> fur<strong>the</strong>r eng<strong>in</strong>eer<strong>in</strong>g <strong>control</strong> measures <strong>in</strong> l<strong>in</strong>e withlegislation <strong>in</strong>clud<strong>in</strong>g upgrad<strong>in</strong>g <strong>of</strong> safe refuge areas and welfare areas are detailed, alongwith monitor<strong>in</strong>g methods, such as air sampl<strong>in</strong>g, wipe test sampl<strong>in</strong>g and biological monitor<strong>in</strong>g,to ensure cont<strong>in</strong>u<strong>in</strong>g high standards.IntroductionSignificant quantities <strong>of</strong> coal tar pitch volatiles (CTPV) that conta<strong>in</strong> relatively highconcentrations <strong>of</strong> <strong>PAH</strong>s are produced dur<strong>in</strong>g <strong>the</strong> cok<strong>in</strong>g process [2]. Without adequate<strong>control</strong>, elevated <strong>exposure</strong>s <strong>of</strong> workers and local communities to <strong>PAH</strong>s can occur.The ma<strong>in</strong> health concerns due primarily to long-term <strong>exposure</strong> are lung and sk<strong>in</strong> cancer, sk<strong>in</strong>problems, and chronic lung diseases such as asthma and bronchitis. Benzo[a]pyrene(B[a]P), a five r<strong>in</strong>ged <strong>PAH</strong>, is classified as a category 1 carc<strong>in</strong>ogen by <strong>the</strong> InternationalAgency for Cancer Research (IARC), mean<strong>in</strong>g that it is a recognised human carc<strong>in</strong>ogen.O<strong>the</strong>r members <strong>of</strong> <strong>the</strong> <strong>PAH</strong> family are considered to be probable (Group 2a) or possible(Group 2b) human carc<strong>in</strong>ogens. Because <strong>of</strong> <strong>the</strong> recognised health risks for coke ovenworkers, Tata Steel Europe (TSE) has demonstrated a strong commitment to <strong>the</strong>identification and implementation <strong>of</strong> effective <strong>control</strong> measures to ensure <strong>the</strong> progressivereduction <strong>of</strong> worker <strong>exposure</strong>s to <strong>PAH</strong>s.The strategy for <strong>the</strong> protection <strong>of</strong> workers follows a set hierarchy <strong>of</strong> <strong>control</strong>s prescribed bycerta<strong>in</strong> local and <strong>in</strong>ternational legislations as identified <strong>in</strong> figure 1. Due to <strong>the</strong> carc<strong>in</strong>ogenicnature <strong>of</strong> <strong>PAH</strong>s, <strong>the</strong>re is a legal and moral responsibility to ensure that <strong>exposure</strong>s are kept aslow as possible, consider<strong>in</strong>g all tiers <strong>of</strong> <strong>the</strong> hierarchy. By successfully implement<strong>in</strong>g andsusta<strong>in</strong><strong>in</strong>g <strong>control</strong> measures, and ensur<strong>in</strong>g on-go<strong>in</strong>g <strong>in</strong>formation, <strong>in</strong>struction and tra<strong>in</strong><strong>in</strong>g isgiven to all workers to re<strong>in</strong>force <strong>the</strong> value <strong>of</strong> <strong>the</strong> <strong>control</strong>s, <strong>the</strong>re will be a cont<strong>in</strong>u<strong>in</strong>g reduction<strong>in</strong> occupational <strong>exposure</strong> to <strong>PAH</strong>s result<strong>in</strong>g <strong>in</strong> reduced risks <strong>of</strong> ill health to coke ovenworkers. Secondary effects <strong>in</strong>clude protect<strong>in</strong>g <strong>the</strong> families <strong>of</strong> coke oven workers byelim<strong>in</strong>at<strong>in</strong>g transfer <strong>of</strong> material from contam<strong>in</strong>ated work clo<strong>the</strong>s, and reduction <strong>in</strong> safety<strong>in</strong>cidents such as grit <strong>in</strong> eye <strong>in</strong>juries due to a significant positive culture change.

Figure1: Hierarchy <strong>of</strong> <strong>control</strong> as advocated by EU and local legislationElim<strong>in</strong>ationSubstitutionProcess Design/SelectionEnclosurePreventionEng<strong>in</strong>eer<strong>in</strong>gLocal ExtractionGeneral VentilationSegregationSafe Work<strong>in</strong>g ProceduresReduction <strong>in</strong> <strong>exposure</strong> timePPE/RPEProceduralWorker BasedExternal Influenc<strong>in</strong>g FactorsS<strong>in</strong>ce <strong>the</strong> start <strong>of</strong> this project, to ensure ongo<strong>in</strong>g compliance with legislation and moralresponsibility, a number <strong>of</strong> o<strong>the</strong>r external factors have provided fur<strong>the</strong>r drivers for ensur<strong>in</strong>gdevelopment <strong>of</strong> adequate <strong>control</strong>. These <strong>in</strong>clude:1. Potential prescription <strong>of</strong> lung cancer as an occupational disease for coke ovenworkers.The Industrial Injuries Advisory Council (IIAC) has advised <strong>the</strong> UK government that <strong>the</strong>re is adoubl<strong>in</strong>g <strong>of</strong> risk <strong>of</strong> develop<strong>in</strong>g lung cancer for personnel work<strong>in</strong>g on a coke oven battery topunder <strong>the</strong> follow<strong>in</strong>g conditions [3]:The prescription is valid for any worker employed <strong>in</strong> activities full time on <strong>the</strong> battery top formore than 5 years, or battery sides for more than 15 years or <strong>in</strong> a comb<strong>in</strong>ation <strong>of</strong> top ovenand o<strong>the</strong>r oven duties, such that each year <strong>in</strong> top oven work be treated as equivalent to 3years work<strong>in</strong>g <strong>in</strong> o<strong>the</strong>r oven duties, <strong>the</strong> aggregated sum amount<strong>in</strong>g to 15 years <strong>in</strong> total. Thisis irrespective <strong>of</strong> smok<strong>in</strong>g, date <strong>of</strong> employment, etc.It is likely that prescription <strong>of</strong> lung cancer, as an occupational disease associated withoccupational <strong>exposure</strong> to hazardous substances at coke ovens, will be confirmed with<strong>in</strong> <strong>the</strong>above limits.2. National Smokeless Fuels (NSF), Phurnacite legal proceed<strong>in</strong>gs.Hundreds <strong>of</strong> ex-workers, and <strong>the</strong> families <strong>of</strong> ex-workers, <strong>of</strong> <strong>the</strong> NSF Phurnacite Plant <strong>in</strong>Abercwmboi, South Wales have brought a group action claim <strong>in</strong> <strong>the</strong> High Court aga<strong>in</strong>st <strong>the</strong>

Department <strong>of</strong> Energy and Climate Change for alleged occupational <strong>exposure</strong> to coke ovenemissions result<strong>in</strong>g <strong>in</strong> respiratory disease and cancer claims from <strong>the</strong> former employees [4].The claimants allege that work<strong>in</strong>g at <strong>the</strong> Phurnacite Plant caused <strong>the</strong>m to suffer lung, sk<strong>in</strong>and bladder cancer as well as respiratory disease. The group action is based around analleged failure to provide <strong>the</strong> necessary protection for <strong>the</strong> workers from <strong>the</strong> potentiallyserious health risks from be<strong>in</strong>g exposed to <strong>the</strong> fumes at <strong>the</strong> plant, which would <strong>in</strong>clude<strong>PAH</strong>s.The trial concluded on <strong>the</strong> 21 December 2011 and judgment is expected <strong>in</strong> 2012.3. Epidemiological studies with <strong>the</strong> Institute <strong>of</strong> Occupational Medic<strong>in</strong>e (IOM)The IOM is currently review<strong>in</strong>g data relat<strong>in</strong>g to lung cancer mortality <strong>in</strong> British coke ovenworkers and assess<strong>in</strong>g <strong>the</strong> effectiveness <strong>of</strong> powered respirators. The results <strong>of</strong> <strong>the</strong>sestudies, which were commissioned by TSE, are expected to be published <strong>in</strong> 2012.4. Penalties for failures to comply with legislation.A number <strong>of</strong> coke ovens worldwide, <strong>the</strong> majority be<strong>in</strong>g <strong>in</strong> <strong>the</strong> USA, have received largepenalties for fail<strong>in</strong>g to protect coke oven workers and communities from coke ovenemissions. The most recent violations <strong>in</strong> 2010 were cited aga<strong>in</strong>st Tonawanda coke ovens,N.Y., USA with <strong>the</strong> company be<strong>in</strong>g f<strong>in</strong>ed $48,500 for 14 alleged serious violations <strong>of</strong>workplace health and safety standards. The citations address deficiencies <strong>in</strong>volv<strong>in</strong>g <strong>the</strong>plant's respiratory protection programme, <strong>the</strong> use <strong>of</strong> personal protective equipment, <strong>in</strong>dustrialhygiene and coke oven operations. Specifically, <strong>the</strong> plant failed to adequately tra<strong>in</strong> workerson respirator selection, use, and to provide adequate storage and ma<strong>in</strong>tenance; ensure <strong>the</strong>use <strong>of</strong> protective cloth<strong>in</strong>g by employees; and to implement work-specific procedures <strong>in</strong> <strong>the</strong>plant's respiratory protection programme.In addition:• The plant did not conduct all required monitor<strong>in</strong>g and perform all required medicalevaluations for workers exposed to coke oven emissions.• Coke spillage was allowed to be shovelled <strong>in</strong>to a heated oven.• There was no provision <strong>of</strong> positive-pressure filtered air to all work cabs.• There was a failure to ma<strong>in</strong>ta<strong>in</strong> mach<strong>in</strong>es <strong>in</strong> good work<strong>in</strong>g order.• Conta<strong>in</strong>ers conta<strong>in</strong><strong>in</strong>g coke-contam<strong>in</strong>ated cloth<strong>in</strong>g were not correctly labelled.• Food and beverages were allowed to be consumed <strong>in</strong> an area with visibleaccumulations <strong>of</strong> coke oven emissions [5].As regulations are similar to EU general and local regulations, <strong>the</strong>se actions aga<strong>in</strong>st <strong>the</strong>company highlight <strong>the</strong> need to comply with legislation and adopt a proactive stance.Tata Steel Europe (TSE) H&S Exposure Reduction ProjectA project to <strong>in</strong>vestigate and <strong>control</strong> <strong>exposure</strong>s to <strong>PAH</strong>s on TSE coke oven batteries has been<strong>in</strong> progress s<strong>in</strong>ce 2009. A number <strong>of</strong> elements <strong>of</strong> <strong>the</strong> programme have been completed asdetailed below: Implementation <strong>of</strong> respiratory protective equipment (RPE) / personal protectiveequipment (PPE) regimes Awareness tra<strong>in</strong><strong>in</strong>g and behavioural <strong>in</strong>vestigations <strong>of</strong> operatives Biological monitor<strong>in</strong>g <strong>of</strong> workers, <strong>in</strong>clud<strong>in</strong>g assessment <strong>of</strong> external laboratories Production and implementation <strong>of</strong> a company wide Code <strong>of</strong> Practice Determ<strong>in</strong>ation <strong>of</strong> safe refuges

Implementation <strong>of</strong> Respiratory Protective Equipment (RPE) / Personal ProtectiveEquipment (PPE) regimesA new replacement powered respirator, encompass<strong>in</strong>g new generation technologies wasidentified through performance, usability and suitability test<strong>in</strong>g for use across all TSE cokeoven plants. The Sundstrom powered respirator has been successfully implemented at allTSE coke oven plants follow<strong>in</strong>g consultations with both coke oven management andoperators. Provision <strong>of</strong> both high efficiency particulate and charcoal filtration demonstratedcommitment to pro-activity with respect to protect<strong>in</strong>g coke oven workers from <strong>PAH</strong>s present<strong>in</strong> both vapour and particulate form. This also affected personal behaviour, as <strong>the</strong> operatorscould no longer detect coke oven emission odours when <strong>the</strong> powered respirators were usedcorrectly. Acceptance has been generally excellent with any operator issues be<strong>in</strong>gresponded to efficiently and opportunities for development fed back to <strong>the</strong> manufacturers.The powered respirator manufacturer has agreed to work closely with TSE to ensurecont<strong>in</strong>u<strong>in</strong>g product development and improve suitability and usability for coke ovenrequirements and to develop and improve a ma<strong>in</strong>tenance regime for <strong>the</strong> units. Sundstromare heavily <strong>in</strong>volved with on-go<strong>in</strong>g <strong>in</strong>formation, <strong>in</strong>struction and tra<strong>in</strong><strong>in</strong>g regard<strong>in</strong>g <strong>the</strong> use andcare <strong>of</strong> <strong>the</strong>ir products.It is now TSE policy for <strong>the</strong> Sundstrom powered respirator to be used <strong>in</strong> all circumstances onTSE coke oven batteries unless identified by a suitable risk assessment that this is notpracticable or <strong>in</strong>duces a fur<strong>the</strong>r safety risk. All situations must be agreed with plantmanagement. Advice has been provided on suitable face seal dependent masks for use <strong>in</strong><strong>the</strong>se situations, along with <strong>in</strong>structions and requirements for <strong>the</strong>ir use.Fur<strong>the</strong>r work is also progress<strong>in</strong>g to ascerta<strong>in</strong> <strong>the</strong> <strong>in</strong>-use protection provided by <strong>the</strong> chosenpowered respirator more accurately and how this protection factor is affected by behaviour.Protective over garments are now distributed from a central communal resource with eachgarment be<strong>in</strong>g returned at <strong>the</strong> end <strong>of</strong> every shift for launder<strong>in</strong>g. Monitor<strong>in</strong>g identified apotential for breakthrough relat<strong>in</strong>g to B[a]P, a category 1 carc<strong>in</strong>ogen, to occur follow<strong>in</strong>gapproximately 20 hours <strong>of</strong> cont<strong>in</strong>uous usage on a battery top. Therefore, to ensure adequate<strong>control</strong>, it was determ<strong>in</strong>ed that a daily change was advantageous. The reduction <strong>in</strong> build up<strong>of</strong> contam<strong>in</strong>ants on <strong>the</strong> garments us<strong>in</strong>g this <strong>control</strong> may affect <strong>the</strong> flame retardant properties,ei<strong>the</strong>r negatively due to <strong>in</strong>creased launder<strong>in</strong>g frequencies, or positively, due to decreasedbuild up <strong>of</strong> contam<strong>in</strong>ation by flammable substances. This is currently under <strong>in</strong>vestigation. Areview <strong>of</strong> current garment material and design is still <strong>in</strong> progress.Figure 2. Implementation and use <strong>of</strong> new RPE/PPE schemes at TSE coke ovens

Investigations <strong>in</strong>to launder<strong>in</strong>g methods identified that garments required dry clean<strong>in</strong>gbecause wet wash<strong>in</strong>g was not effective at remov<strong>in</strong>g <strong>PAH</strong>s from <strong>the</strong> cloth and resulted <strong>in</strong>cross-contam<strong>in</strong>ation <strong>of</strong> clean garments. Therefore, dry clean<strong>in</strong>g is now <strong>the</strong> normal policy atall TSE’s UK coke oven plants.A wide variety <strong>of</strong> gloves were <strong>in</strong> use across TSE’s UK coke oven plants. This has beenreduced to three standard lea<strong>the</strong>r glove types vary<strong>in</strong>g <strong>in</strong> properties, exempted only by agreedrisk assessment.Implementation <strong>of</strong> TSE Code <strong>of</strong> PracticeA TSE Code <strong>of</strong> Practice (CoP) [6] has been prepared and issued follow<strong>in</strong>g consultation withcoke oven management and trade union personnel.Application <strong>of</strong> <strong>the</strong> CoP across all TSE coke oven plants is mandatory and covers allpersonnel employed <strong>in</strong>clud<strong>in</strong>g contractors.The CoP re<strong>in</strong>forces local legislation or provides<strong>in</strong>struction where this is lack<strong>in</strong>g.Figure 3. TSE Code <strong>of</strong> PracticeThe objectives <strong>of</strong> <strong>the</strong> Code <strong>of</strong> Practice are: to ensure that suitable and sufficient riskmanagement strategies are established and <strong>in</strong>place to reduce <strong>exposure</strong>s to <strong>PAH</strong>s to as low alevel as is reasonably practicable; to allow identification and prioritisation <strong>of</strong> <strong>the</strong>resources required to deliver <strong>the</strong> strategies; to ensure that common risks at all TSE cokeoven plants are managed to <strong>the</strong> same standard; to ensure that all personnel understand <strong>the</strong> risksassociated with work<strong>in</strong>g <strong>in</strong> a coke ovenenvironment and how to safely m<strong>in</strong>imise <strong>the</strong>serisks; to ensure that any established risk reductionand <strong>control</strong> strategies are audited annually with<strong>the</strong> results be<strong>in</strong>g reported to site management.A gap analysis between current situations and requirements <strong>of</strong> <strong>the</strong> CoP has been undertakenat all plants, with determ<strong>in</strong>ation <strong>of</strong> common short-term strategies be<strong>in</strong>g shared and deployed.Smok<strong>in</strong>g and eat<strong>in</strong>g on TSE coke oven plantsSmok<strong>in</strong>g and eat<strong>in</strong>g on coke oven batteries have been identified as major contributors to<strong>in</strong>creased <strong>exposure</strong>s to <strong>PAH</strong>s, <strong>in</strong>clud<strong>in</strong>g B[a]P. There is also evidence <strong>of</strong> <strong>in</strong>creased risk <strong>of</strong>contract<strong>in</strong>g lung cancer if people smoke and are occupationally exposed to carc<strong>in</strong>ogens suchas B[a]P.Both UK and EU legislation state that smok<strong>in</strong>g, eat<strong>in</strong>g and dr<strong>in</strong>k<strong>in</strong>g should not occur where<strong>the</strong>re is a potential for a carc<strong>in</strong>ogen to be present. However, due to more immediate risksrelat<strong>in</strong>g to <strong>the</strong> potential for heat-<strong>in</strong>duced ill health, it has been determ<strong>in</strong>ed by risk assessmentthat dr<strong>in</strong>k<strong>in</strong>g must be permitted with <strong>in</strong>structions for personnel to move from high risk <strong>PAH</strong><strong>exposure</strong> areas to dr<strong>in</strong>k.

All TSE coke oven personnel, safety teams and management are aware <strong>of</strong> <strong>the</strong> govern<strong>in</strong>gprecedence and re<strong>in</strong>forcement <strong>of</strong> no smok<strong>in</strong>g and no eat<strong>in</strong>g policies on <strong>the</strong> batteries, whichhave been streng<strong>the</strong>ned us<strong>in</strong>g discipl<strong>in</strong>ary procedures where required. Designated areashave been identified through monitor<strong>in</strong>g concentrations <strong>of</strong> B[a]P <strong>in</strong> air for <strong>the</strong> erection <strong>of</strong>smok<strong>in</strong>g shelters. Signage has been updated to identify <strong>the</strong> presence <strong>of</strong> carc<strong>in</strong>ogens on <strong>the</strong>coke oven battery, to re<strong>in</strong>force no smok<strong>in</strong>g and no eat<strong>in</strong>g and to determ<strong>in</strong>e <strong>the</strong> entire batteryfrom bench level up as a mandatory PPE/RPE zone.Job RotationJob location and duration significantly affects potential <strong>exposure</strong>s to <strong>PAH</strong>s with operatorsemployed on a battery top for long periods <strong>of</strong> time be<strong>in</strong>g at <strong>the</strong> highest risk and operatorssituated away from <strong>the</strong> battery, such as <strong>the</strong> coke car operators, hav<strong>in</strong>g low risk as identified<strong>in</strong> Graph 1. It is recommended that job rotation should be employed on all TSE sites toreduce <strong>the</strong> risk <strong>of</strong> excessive <strong>exposure</strong> for all operators. This would also result <strong>in</strong> a multiskilled workforce.The current situation at TSE coke ovens is that not all coke oven plants are engaged <strong>in</strong> arobust formal job rotation programme and where <strong>the</strong>y exist, <strong>the</strong>re is variation <strong>in</strong> rotationpatterns. As a m<strong>in</strong>imum it has been determ<strong>in</strong>ed that job rotation should occur on a shiftbasis, with no operator be<strong>in</strong>g situated on <strong>the</strong> battery top for more than one shift wherepossible. This strategy will be developed gradually due to <strong>the</strong> tra<strong>in</strong><strong>in</strong>g demands required forimplementation and to allow <strong>in</strong>tegration <strong>of</strong> specialist jobs where possible.Graph 1. Graph to identify how <strong>exposure</strong> varies with job description and location.Below HSE andTSE <strong>in</strong> housebiological monitor<strong>in</strong>gguidance values*Below HSE butabove TSE <strong>in</strong> housebiological monitor<strong>in</strong>gguidance values*Above HSE andTSE <strong>in</strong> housebiological monitor<strong>in</strong>gguidance values*> x2 HSE biologicalmonitor<strong>in</strong>g guidancevalue** The results are based on biological monitor<strong>in</strong>g <strong>of</strong> coke oven operators prior to upgrad<strong>in</strong>g <strong>of</strong> <strong>control</strong>s. The Health andSafety Executive (HSE) have recommended a guidance value associated with biological monitor<strong>in</strong>g to identify when<strong>control</strong> is considered achievable.

Provision <strong>of</strong> <strong>in</strong>formation, <strong>in</strong>struction and tra<strong>in</strong><strong>in</strong>g.All personnel (employees and third parties) who by <strong>the</strong> nature <strong>of</strong> <strong>the</strong>ir work have <strong>the</strong> potentialto be exposed to <strong>PAH</strong>s must receive suitable and sufficient <strong>in</strong>formation, <strong>in</strong>struction andtra<strong>in</strong><strong>in</strong>g. This should cover potentially adverse health risks, <strong>control</strong>s <strong>in</strong> place and <strong>the</strong>ir usageand company expectations <strong>of</strong> <strong>the</strong> employees. The <strong>in</strong>formation and tra<strong>in</strong><strong>in</strong>g should berefreshed at regular <strong>in</strong>tervals.The majority <strong>of</strong> coke oven operators and management across TSE coke oven plants havereceived <strong>in</strong>itial awareness sessions to accommodate <strong>the</strong> above requirements. The provisionand delivery <strong>of</strong> this has been <strong>the</strong> s<strong>in</strong>gle, most effective method <strong>of</strong> reduc<strong>in</strong>g <strong>exposure</strong>s,especially when used with strategies such as ‘bro<strong>the</strong>r’s keeper’, etc. Peer pressure andreview have been <strong>in</strong>strumental <strong>in</strong> ensur<strong>in</strong>g that all personnel, both workforce andmanagement, understand, engage and will<strong>in</strong>gly partake <strong>in</strong> <strong>the</strong> <strong>exposure</strong> <strong>control</strong> policy.A package is currently under development to provide <strong>in</strong>teractive annual refresher tra<strong>in</strong><strong>in</strong>gand cont<strong>in</strong>u<strong>in</strong>g awareness through posters and o<strong>the</strong>r visible literature. This is a jo<strong>in</strong>t venture<strong>in</strong>volv<strong>in</strong>g occupational hygienists, site management, safety teams and behavioural experts.Figure 4. Examples <strong>of</strong> awareness tra<strong>in</strong><strong>in</strong>g materialSafe refuges at TSE coke ovensWorkers should be segregated where possible from <strong>the</strong> battery environment by measuressuch as <strong>the</strong> provision <strong>of</strong> ‘safe refuges’. These safe refuges should provide an environmentthat elim<strong>in</strong>ates, as far as practicable, occupational <strong>exposure</strong>s to <strong>PAH</strong>s. These areas shouldallow <strong>the</strong> relaxation from use <strong>of</strong> RPE/PPE and provide safe areas for operators to dr<strong>in</strong>k.Areas designated as safe refuges <strong>in</strong>clude welfare facilities, mess rooms, <strong>control</strong> rooms andwhere available mach<strong>in</strong>e <strong>control</strong> cab<strong>in</strong>s.In accordance with <strong>the</strong> TSE CoP, concentrations <strong>of</strong> B[a]P <strong>in</strong> air <strong>in</strong> <strong>the</strong>se areas should be aslow as possible, not exceed<strong>in</strong>g 0.15 µg/m 3 . This limit was determ<strong>in</strong>ed for <strong>the</strong> follow<strong>in</strong>greasons:1. It equated to <strong>the</strong> current workplace <strong>exposure</strong> limits as advised <strong>in</strong> <strong>the</strong> Ne<strong>the</strong>rlands and <strong>the</strong>lowest workplace <strong>exposure</strong> limits set <strong>in</strong> o<strong>the</strong>r countries (namely France).2. It had been demonstrated as be<strong>in</strong>g achievable.

3. The correlat<strong>in</strong>g risk associated with chronic workplace <strong>exposure</strong> at this level is 4 deaths <strong>in</strong>10,000 (1 <strong>in</strong> 2,500) workers accord<strong>in</strong>g to <strong>the</strong> Ne<strong>the</strong>rlands’ 'health-based calculatedoccupational cancer risk values' follow<strong>in</strong>g occupational <strong>exposure</strong> to B[a]P [7].Legislation [8] prescribes that <strong>the</strong>se areas should undergo regular clean<strong>in</strong>g <strong>in</strong>clud<strong>in</strong>g <strong>the</strong>wip<strong>in</strong>g <strong>of</strong> walls and floors.Initial audits and sampl<strong>in</strong>g undertaken at Tata Steel’s UK coke oven plants identifieddifferences <strong>in</strong> availability <strong>of</strong> safe refuges, <strong>the</strong> <strong>control</strong> systems available, <strong>the</strong> ma<strong>in</strong>tenance andclean<strong>in</strong>g regimes, and <strong>the</strong> conditions <strong>of</strong> areas considered safe refuges. Welfare facilities and<strong>of</strong>fices generally conformed to <strong>the</strong> requirements for designation, however, mach<strong>in</strong>e <strong>control</strong>cab<strong>in</strong>s did not, and so <strong>the</strong>se were identified as a priority for upgrad<strong>in</strong>g especially <strong>in</strong> high<strong>exposure</strong> risk areas such as <strong>the</strong> battery top.Immediate recommendations result<strong>in</strong>g from audits <strong>in</strong>volved: implementation or upgrad<strong>in</strong>g <strong>of</strong> air filtration systems replacement <strong>of</strong> w<strong>in</strong>dows and door seals upgrad<strong>in</strong>g <strong>of</strong> air condition<strong>in</strong>g units to motivate operators to keep external doorsclosedA number <strong>of</strong> actions resulted:1. An air filtration unit has been identified for trial tak<strong>in</strong>g <strong>in</strong>to account <strong>the</strong> follow<strong>in</strong>g factors: Must be able to provide adequate protection to allow compliance with <strong>the</strong> TSE CoP. Must <strong>in</strong>corporate high efficiency particulate and charcoal filtration. Must have a sta<strong>in</strong>less steel structure to withstand a coke oven environment. Should be multi-functional to draw <strong>in</strong> air from external source and/or recirculate onvariable speed as required. Spare parts and consumables must be available at short notice <strong>in</strong> case <strong>of</strong>emergencies. Should be situated <strong>in</strong>side <strong>the</strong> cab<strong>in</strong> and be compatible with <strong>the</strong> current electricitysupply. Must be provided with an adequate and effective ma<strong>in</strong>tenance regime <strong>in</strong>clud<strong>in</strong>g filtermedia performance determ<strong>in</strong>ation. The ma<strong>in</strong>tenance regime should be compatible with <strong>the</strong> exist<strong>in</strong>g ma<strong>in</strong>tenancecontract companies. Must be available for supply and <strong>in</strong>stallation to all TS UK sites.2. Potentially suitable vacuum clean<strong>in</strong>g systems have been identified and obta<strong>in</strong>ed for trial toassist with rout<strong>in</strong>e clean<strong>in</strong>g <strong>of</strong> cab<strong>in</strong>s.3. Replacement <strong>of</strong> unsatisfactory cab<strong>in</strong> doors and w<strong>in</strong>dow seals has commenced.4. Air condition<strong>in</strong>g systems have been <strong>in</strong>vestigated and more suitable systems identified.5. Mach<strong>in</strong>e cab<strong>in</strong>s will undergo complete ma<strong>in</strong>tenance prior to <strong>in</strong>stallation <strong>of</strong> <strong>the</strong>se systems.This <strong>in</strong>cludes repairs to doors and w<strong>in</strong>dow seals and ‘box<strong>in</strong>g <strong>in</strong>’ <strong>of</strong> cables to leave smoothsurfaces.With respect to cleanl<strong>in</strong>ess <strong>of</strong> welfare facilities, mess rooms and <strong>of</strong>fices, it is appreciated thata stricter level <strong>of</strong> decontam<strong>in</strong>ation may be required to ensure that <strong>in</strong>advertent <strong>exposure</strong>, suchas <strong>in</strong>gestion, does not occur. To ensure that standards are ma<strong>in</strong>ta<strong>in</strong>ed, clean<strong>in</strong>g regimes arecurrently under review and a strategy has been implemented whereby respiratory protectiveequipment and personal protective equipment is removed as far as possible prior to enter<strong>in</strong>g

<strong>of</strong> <strong>the</strong>se facilities. A ‘wipe test’ and an appropriate guidance value are be<strong>in</strong>g developed toallow rout<strong>in</strong>e monitor<strong>in</strong>g <strong>of</strong> <strong>the</strong> work<strong>in</strong>g environment and effectiveness <strong>of</strong> <strong>the</strong> clean<strong>in</strong>gregimes.Exposure assessments at TSE coke ovensBiological monitor<strong>in</strong>g is an effective way <strong>of</strong> determ<strong>in</strong><strong>in</strong>g <strong>in</strong>dividual <strong>exposure</strong>s to <strong>PAH</strong>s via allpotential routes and ensur<strong>in</strong>g ongo<strong>in</strong>g effectiveness <strong>of</strong> <strong>the</strong> adopted <strong>control</strong> measures.Exposure to <strong>PAH</strong>s are determ<strong>in</strong>ed by measur<strong>in</strong>g a metabolite (1-hydroxypyrene) <strong>of</strong> one <strong>of</strong><strong>the</strong> <strong>PAH</strong> family (pyrene) <strong>in</strong> ur<strong>in</strong>e.The TSE CoP provides an <strong>in</strong>itial biological monitor<strong>in</strong>g guidance value (BMGVs) <strong>of</strong> 4 µmol 1-hydroxypyrene/ mol creat<strong>in</strong><strong>in</strong>e* to correspond with a guidance value set <strong>in</strong> <strong>the</strong> UK by HSE.This is not health based but is a practicable, achievable level set at <strong>the</strong> 90th percentile <strong>of</strong>available biological monitor<strong>in</strong>g results collected from a representative sample <strong>of</strong> workplaceswith good occupational hygiene practices. If a result is greater than <strong>the</strong> BMGV it does notnecessarily mean that ill health will occur, but it does <strong>in</strong>dicate that <strong>control</strong> <strong>of</strong> <strong>exposure</strong> maynot be adequate or that an <strong>in</strong>dividual’s work<strong>in</strong>g methods or use <strong>of</strong> <strong>control</strong>s may be below <strong>the</strong>required standard. Under <strong>the</strong>se circumstances employers will need to look at current workpractices to see how <strong>the</strong>y can be improved to reduce <strong>exposure</strong> [9].A fur<strong>the</strong>r <strong>in</strong>-house guidance value has been established by TSE at 2 µmol 1- hydroxypyrene/mol creat<strong>in</strong><strong>in</strong>e. This value is representative <strong>of</strong> very low levels <strong>of</strong> occupational <strong>exposure</strong>consider<strong>in</strong>g <strong>the</strong> background population <strong>in</strong>clud<strong>in</strong>g heavy smokers, and should be achievable ifall <strong>control</strong> measures are adequate and used correctly.Operators employed at <strong>the</strong> coke ovens will be required to undergo biological monitor<strong>in</strong>g aspart <strong>of</strong> <strong>the</strong>ir rout<strong>in</strong>e health surveillance. The frequency <strong>of</strong> monitor<strong>in</strong>g is determ<strong>in</strong>ed by <strong>the</strong>operator’s potential risk <strong>of</strong> <strong>exposure</strong> and <strong>exposure</strong> history. Roll<strong>in</strong>g programmes have beendevised where not already <strong>in</strong> place to ensure ongo<strong>in</strong>g assessment <strong>of</strong> employee’s <strong>exposure</strong>sand efficiency <strong>of</strong> <strong>the</strong> <strong>control</strong>s currently <strong>in</strong> place along with <strong>the</strong>ir ma<strong>in</strong>tenance regimes.* Creat<strong>in</strong><strong>in</strong>e is produced at a constant rate with<strong>in</strong> <strong>the</strong> human body and can be used <strong>in</strong> analysis to correct forde/hydration and normalise results. Conversion: 1mol/mol = 1.93 µg/gResults – Improvements <strong>in</strong> behaviours and reduction <strong>in</strong> <strong>exposure</strong>s due to <strong>control</strong>simplementedThe outcome <strong>of</strong> all <strong>control</strong> measures implemented to date was immediately seen and<strong>in</strong>cluded: Increased awareness and knowledge <strong>of</strong> <strong>the</strong> operators, result<strong>in</strong>g <strong>in</strong> visibleimprovement <strong>in</strong> <strong>the</strong> use <strong>of</strong> available <strong>control</strong> measures <strong>in</strong> behavioural audits. Lower results from biological monitor<strong>in</strong>g, as shown <strong>in</strong> Figs 5 and 6, identify<strong>in</strong>greduced <strong>exposure</strong>s, through all routes, <strong>of</strong> 63.5% (representative average).Demonstration that biological monitor<strong>in</strong>g guidance values can be achieved even <strong>in</strong>employees, who have <strong>the</strong> greatest levels <strong>of</strong> <strong>exposure</strong>, provided <strong>the</strong> <strong>control</strong> measuresare <strong>in</strong> place. Successful collaboration across all TSE coke oven plants. Identification <strong>of</strong> approximately £100k cost sav<strong>in</strong>g opportunities by develop<strong>in</strong>gprotocols for us<strong>in</strong>g shared fan units and issu<strong>in</strong>g personal helmets as RPE options andthrough optimisation <strong>of</strong> filtration change frequency and review <strong>of</strong> exist<strong>in</strong>g hand andsk<strong>in</strong> protection.

109.598.587.576.565.554.543.532.521.510.5109.598.587.576.565.554.543.532.521.510.50.70.60.11110.5109.598.587.576.565.554.543.532.521.510.51211.51110.5109.598.587.576.565.554.543.532.521.510.51.911.32.4 2.34.42.70.19.35.50.12.09.410.52.84.60.94.92.95.80.90.12.43.6111.55.8 A significant reduction (80%) <strong>in</strong> dust <strong>in</strong> eye <strong>in</strong>cidents, which is attributed to <strong>the</strong> correctusage and re<strong>in</strong>forcement <strong>of</strong> RPE/PPE provided. Whilst this is not a high severityharm, it has been a frequent first aid <strong>in</strong>jury at TSE’s coke ovens.Figure 5. Results <strong>of</strong> pre- and post-<strong>control</strong> implementation biological monitor<strong>in</strong>g <strong>of</strong><strong>exposure</strong> to <strong>PAH</strong>s at TSE coke oven plant 1Prior to <strong>PAH</strong> project awareness tra<strong>in</strong><strong>in</strong>g andwear<strong>in</strong>g airstream helmets and non daily overallchangeSamples taken dur<strong>in</strong>g <strong>PAH</strong> reduction project.Operators received awareness tra<strong>in</strong><strong>in</strong>g andSundstrom helmet but daily change overalls hadnot yet been implemented.Biological Determ<strong>in</strong>ant 1-Hydroxy-Pyrene (mol/Mol Creat<strong>in</strong><strong>in</strong>e) 1-Hydroxy-Pyrene (mol/Mol Creat<strong>in</strong><strong>in</strong>e)OccupationHeaterTeam Leader4.96.2Pusher7.61.2(LC)Battery TopBattery TopBattery Top44.57.0 1.321,5 (LC) 2.54.6Coke Car2.1Coke CarTata Steel (UK)Internal Action Limit0.5 0.82.0 2.0Figure 6. Initial results <strong>of</strong> pre- and post-<strong>control</strong> implementation biological monitor<strong>in</strong>gfor <strong>exposure</strong> to <strong>PAH</strong>s at TSE coke oven plant 2Pre Control implementation biological monitor<strong>in</strong>gresults (1-Hydroxy-Pyrene (µmol/Mol Creat<strong>in</strong><strong>in</strong>e))Post Control implementation biologicalmonitor<strong>in</strong>g results (1-Hydroxy-Pyrene (µmol/MolCreat<strong>in</strong><strong>in</strong>e))OccupationTeam Member 1Team Member 2Team Member 3Team Member 4Team Member 5Team Member 6Team Member 7Team Member 8Team Member 9Team Member (Act<strong>in</strong>g TeamLeader)Hea<strong>the</strong>r-Man 1Hea<strong>the</strong>r-Man 2Environmental PollutionControl OperatorProcess Co-ord<strong>in</strong>ator2.8 2.7Tata Steel (UK)Internal Action Limit2.02.0HSE Guidance Limit4.0 4.0Long-term strategies - Controll<strong>in</strong>g emissions at sourceThe most effective way <strong>of</strong> protect<strong>in</strong>g both <strong>the</strong> workforce and <strong>the</strong> local community is through<strong>the</strong> use <strong>of</strong> long-term eng<strong>in</strong>eer<strong>in</strong>g methods. There is ever <strong>in</strong>creas<strong>in</strong>g legislative pressure toensure that this is <strong>the</strong> case and so strategies are be<strong>in</strong>g formulated at TSE coke oven plantsto consider improvements. However, <strong>the</strong> lifespan <strong>of</strong> coke ovens is currently be<strong>in</strong>g extended

well beyond 30 years and new <strong>in</strong>novative technologies may not be easy to retr<strong>of</strong>it. Therefore,adequate ma<strong>in</strong>tenance <strong>of</strong> current technologies and equipment is <strong>of</strong> primary importance.A European project undertaken between 2003 and 2007 determ<strong>in</strong>ed that <strong>the</strong> most significantsource <strong>of</strong> fugitive emissions resulted from door leakage that may contribute up to 88% <strong>of</strong>total <strong>PAH</strong> concentration <strong>in</strong> a given area [10, 11]. This highlights <strong>the</strong> importance <strong>of</strong> reduc<strong>in</strong>gsuch emissions. Many <strong>in</strong>vestigations <strong>in</strong>to technologies and upgrades that require capitalexpenditure are underway <strong>in</strong>clud<strong>in</strong>g <strong>in</strong>spection <strong>of</strong> new technologies to allow better extractionand replacement <strong>of</strong> doors.Susta<strong>in</strong>abilityPolicies have been devised to ensure that <strong>the</strong> improvements already implemented aresusta<strong>in</strong>ed, and to ensure <strong>the</strong> cont<strong>in</strong>uous improvement and development <strong>of</strong> <strong>control</strong> <strong>of</strong><strong>exposure</strong> to <strong>PAH</strong>s. These <strong>in</strong>clude:• Cont<strong>in</strong>uous <strong>in</strong>ternal and external audits and reviews to ensure on-go<strong>in</strong>gconformation <strong>of</strong> <strong>control</strong> adequacy.• Complete review <strong>of</strong> all current ma<strong>in</strong>tenance schedules and contracts.• Gap analysis and subsequent implementation <strong>of</strong> requirements as described <strong>in</strong> <strong>the</strong>company wide Code <strong>of</strong> Practice.• Regular shar<strong>in</strong>g and learn<strong>in</strong>g sessions attended by all TSE coke oven plantpersonnel.• Cont<strong>in</strong>uation <strong>of</strong> management strategies (e.g. <strong>in</strong>formation provision,re<strong>in</strong>forcement).• Involvement from safety departments/specialistsAcknowledgementsMany people have been <strong>in</strong>volved <strong>in</strong> this jo<strong>in</strong>t project and all deserve credit for <strong>the</strong>ircont<strong>in</strong>uous hard work and effort, and for try<strong>in</strong>g to make a difference. These <strong>in</strong>clude:• Port Talbot site health hygienists• Scunthorpe site hygienists• Tata Steel Group Environment• All coke oven management for <strong>the</strong>ir cont<strong>in</strong>uous support and buy-<strong>in</strong>• The operators at all sites who have been <strong>in</strong>volvedReferences1. Wilcox, D., Conroy, T.M., Azam, J., & Anderson, D.R., ‘Control <strong>of</strong> Coke OvenWorkers Exposure to Polycyclic Aromatic Hydrocarbons’, The Year-Book <strong>of</strong> <strong>the</strong> CokeOven Managers Association 2011, pg 164-181.2. Fisher R. and He<strong>in</strong> M., ‘Environmental <strong>control</strong> <strong>of</strong> European coke plants at <strong>the</strong>beg<strong>in</strong>n<strong>in</strong>g <strong>of</strong> <strong>the</strong> 21 st century’, Proceed<strong>in</strong>gs <strong>of</strong> <strong>the</strong> 4 th European Coke and Ironmak<strong>in</strong>gCongress, June 19-22, 2000, Paris La Defense, France, pg 541-5463. Department <strong>of</strong> Work and Pensions Social Security Adm<strong>in</strong>istration Act 1992, ‘Lungcancer <strong>in</strong> coke oven workers: Report by <strong>the</strong> Industrial Injuries Advisory Council <strong>in</strong>accordance with Section 171 <strong>of</strong> <strong>the</strong> Social Security Adm<strong>in</strong>istration Act 1992consider<strong>in</strong>g prescription for lung cancer <strong>in</strong> coke oven workers’. Presented toParliament by <strong>the</strong> Secretary <strong>of</strong> State for Work and Pensions By Command <strong>of</strong> HerMajesty September 2011, ISBN: 9780101816328.

4. Correspondence from Hugh James solicitors, appo<strong>in</strong>ted by <strong>the</strong> High Court to be <strong>the</strong>lead solicitor act<strong>in</strong>g for ex-workers and families <strong>in</strong> <strong>the</strong> Phurnacite Group Litigation.5. United States Department <strong>of</strong> Labour, Office <strong>of</strong> Public Affairs, OSHA Regional NewsRelease, Release no. 10-543-NEW B05 2010-199, 7 th May 2010.6. Tata Steel Europe Health and Safety Code <strong>of</strong> Practice: HSC-28.1 Revision 1 (22-07-2011): Manag<strong>in</strong>g <strong>the</strong> risks associated with <strong>exposure</strong> to polycyclic aromatichydrocarbons <strong>in</strong> <strong>the</strong> coke oven battery work<strong>in</strong>g environment7. Dutch Expert Committee on Occupational Standards; a committee <strong>of</strong> <strong>the</strong> HealthCouncil <strong>of</strong> <strong>the</strong> Ne<strong>the</strong>rlands, BaP and <strong>PAH</strong> from coal derived sources; Health-basedcalculated occupational cancer risk values <strong>of</strong> benzo[a]pyrene and unsubstituted nonheterocyclicpolycyclic aromatic hydrocarbons from coal derived sources, No.2006/01OSH, The Hague, 21 February 20068. DIRECTIVE 2004/37/EC OF THE EUROPEAN PARLIAMENT AND OF THECOUNCIL <strong>of</strong> 29 April 2004 on <strong>the</strong> protection <strong>of</strong> workers from <strong>the</strong> risks related to<strong>exposure</strong> to carc<strong>in</strong>ogens or mutagens at work (Sixth <strong>in</strong>dividual Directive with<strong>in</strong> <strong>the</strong>mean<strong>in</strong>g <strong>of</strong> Article 16(1) <strong>of</strong> Council Directive 89/391/EEC).9. Health and Safety Commission Advisory Committee on Toxic Substances, PolycyclicAromatic Hydrocarbons, A <strong>control</strong> approach, A Paper by Richard PedersenAdvisor(s): Mart<strong>in</strong> Stear Cleared by John Thompson on 5 June 200310. Emissions Reduction through Analysis, Modell<strong>in</strong>g and Control, (ERAMAC), ResearchFund for Coal and Steel Programme, (ERAMAC-RFCS-CR-03001); coord<strong>in</strong>ator DRAnderson, 2007.11. Fugitive and Stationary Source Emissions from Coke Plants and Impact on <strong>the</strong> LocalAmbient Air Quality, E. Aries, D. Ciaparra, M. J. Sch<strong>of</strong>ield, D. R. Anderson, N.Sch<strong>of</strong>ield and R. Fisher, The Year Book <strong>of</strong> <strong>the</strong> Coke Oven Managers Association2009, pg 136-197 .