Document 0vDp4doK2yrzwOZ3Dx49qvYx

067986 Industrial Hygiene Survey ^j Brook Plant - 1974 ; rW \ 3 j cCr y*t INDUSTRIAL HYGIENE SURVEY OF VINYL FABRICS DIVISION BOUND BROOK. NEW JERSEY BY W. D. NEAL PLANT 312 INDUSTRIAL HYGIENIST JUNE 1974 SAFETY AMD ENVIRONMENTAL PROTECTION DEPARTMENT UNION CARBIDE CORPORATION CHEMICALS AND PLASTICS DIVISION BOUND BROOK, NEW JERSEY t & ucc 06798? TABLE OF CONTENTS INTRODUCTION.....................................................................Pg 1 SUMMARY Vinyl Chloride......................... Page 2 Solvent Vapor........................................................... Page 3 Dust...............................................................................Page 3 Ventilation................................................................Page 3 Noise.............................................................................Page 3 Lighting...................................................................... Page 3 Radiation.................................................................... Page 3 RECOMMENDATIONS Vinyl Chloride......................................................... Page 4 Solvent Vapor......... ............................................... Page 4 Dust.............................................................................. Page 4 Ventilation............................................................... Page 5 Noise............................................................................ Page 5 Lighting......................................................................Page 5 DISCUSSION OF TEST METHODS Vinyl Chloride.........................................................Page 5 Solvent Vapor...........................................................Page 6 Dust.............................................................................Page 6 Noise............................................................................Page 6 Lighting............................. Page 6 Radiation................................................................... Page 6 Ventilation............................................... Page 6 DISCUSSION OF TEST RESULTS Vinyl Chloride........ ............................................. Page 7 Solvent Vapor.......................................................... Page 9 Dust..............................................................................Page 11 .......................................................................................Page 11 Lighting.................................................................... Page 12 Radiation................................................................... Page 13 APPENDIX........................................................................... Page 14 ACKNOWLEDGEMENTS.......................................................... Page 20 ucc 067988 INTRODUCTION An Industrial Hygiene survey was conducted In the Vinyl Fabrics Division from late April through Hay to evaluate such health stresses as dusts, chemical vapors, noise, etc. against OSHA thres hold limit values and generally recognised good Industrial Hygiene practice. Particular attention was given to vinyl chloride as an air contaminant now under strict regulations as a carcinogen. The vinyl chloride portion of the survey was coordinated to enable compliance with the OSHA emergency standard which required three consecutive weeks of monitoring comnencing April 22. The survey also incorporated a sampling program request ed by Hr. R. N. Wheeler for vinyl chloride impact studies. Page 1 ucc 067989 SUMMARY Vinyl Chloride - Calendering Lines. Building 105, and Building 101. Bay 15 Ambient air on the first floor level contains no more than 1 ppm vinyl chloride, while ambient air on the blender mezzanine measures up to 7 ppm, the probable source of contamination being the blenders which, when charged with suspension type (QSAH and QSAN) resins, generate up to 4500 ppm vinyl chloride In their head spaces. Roof exhausts from the extruder and calender fume removal systems do not exceed 6 ppm. (See schematic, Appendix, Figure 1.) Personnel taking preblend samples from blenders occasionally encountered exposures of up to 175 ppm for periods of less than a minute due to the escape of volatiles when the blenders were opened. Abatement measures arc in progress, including addition of controls which permit purging of contaminated air from each blender prior to the operator opening the sampling port. This should eliminate the excursions and reduce the levels in the ambient air by minimiz ing the escape of vinyl chloride contaminated air into the work area. Vinyl Chloride - Foam Lines Vinyl chloride measured in the 1+0.5 ppm range during the bag-dumping of resin into mix tanks. The dispersion-type resins In use contain low residual monomer. Measurements at the oven exits by Miran indicated <1 ppm vinyl chloride in the oven smoke. Vinyl Chloride - Bulk Resin Unloading Vinyl chloride in the head space of van boxes in storage measured in the 2000 4500 ppm range. However, exposure to personnel during hook-up of the boxes for unloading into alrveyors is limited to the 2+1 ppm range. OSHA Inspection for Vinyl Chloride A Region 2 OSHA Industrial Hygienist started a vinyl chloride inspection June 20 and 21, but monitoring was interrupted when Line 1000 ran out due to shortage of resin. The inspection is expected to be continued at a later date under normal production conditions. notification of Baploveaa In order to clarify the vinyl chloride situation as regards to Bound Brook employees, eight informational meetings were held on overtime for shift and day employees working in the Building 105 calendering and foam line areas; Building 101- Bay 10, Bay 15 and resin airveyor operators, mechanics, union safety comitteemen and union president. A 20 siinute presentation included the back ground of events that led to the proasilgatlon of the April 5, 1974 emergency temporary standard for vinyl chloride. Data determined from the survey was presented with precautionary procedures for avoiding potential exposure, followed by a question and answer period. Page 2 ucc 067990 Solvent Vapor - Ink Preparation and Printer Room. Building 105 Exposure of operators tending the printers averaged 40 to 50% of allowable dosage, while those preparing strike-offs and ink mixes averaged In the 53 to 707, range. The area of the test bench in the ink room averaged 67 to 92%, indicating the.desirability of better ventilation or containment of solvents. Dusts - Building 105 Exposure of blender operators when resin is charged from tanks is 33% of the allowable TWA of 15 mg./cu. meter for nuisance (inert) dust. However, exposure exceeds the limit when blender operators hand-dump QYNA and other dusty powders into L-1000 blenders without ventilation. (Ventilation has since been provided, essentially eliminating the problem.) Operators in the foam mix room receive excessive exposure to resin dust while dumping bags of dispersion resin in the preparation of "skin" plastisols. The ventilation system for both mix dissolvers emits vlsable dust from the roof exhaust fan during bag dumping. Ventilation All systems were in operation except the Dynaclone which was operated intermit tently , the Trans-Valr system which was plugged, and the hood exhaust for the small weigh-ups on the blender floor. The first two systems have since been restored to continuous service. Noise There are no work stations where noise exceeds 90 dBA. Readings up to 96 d&A measured in close proximity to the FCM gear reducers and Line 1000 trim cutter indicate a need to post signs restricting exposure time or the Installation f sound-proofing. Lighting Lighting is satisfactory except in certain warehouse areas, blender operating aisle, and shower rooms which are below ANSI standards. Radiation All eight sources tested satisfactorily. Page 3 ucc 067991 RECOMMENDATIONS Vinyl Chloride Abatement Inroodlate I. Caution blender operators against inhalation of odiferous fumes (hydrocarbon solvents, etc.) which may alao carry vinyl chloride. To avoid inhalati n of such fumes, make certain operators use long-handled scoops and stand away from sample port for at least one minute after opening port before sampling. (This has been done.) Interim 2. Adjust vent valves on blenders to continuously purge air and vapors from blenders during blending and discharge, thereby avoiding build-up of vinyl chloride in the air space of the blenders. 3. Provide controls for applying full exhaust on blenders during sampling and entry for cleaning or repairs, thereby preventing escape of contaminated air and protecting personnel working in blenders. Longer-Term 4. Reduce residual monomer content of feedstock resins. 5. Provide a back-up ventilation system to permit continuity of operations in the event of outage of the existing system. Blenders should not be operated without adequate ventilation unless operators are supplied with air-supplied or self-contained breathing apparatus. 6. Install a local exhaust system on the Bay 15 blenders in Building 101, none existing at present. Solvent Vapors Abatement 1. Replace open containers (pails, dixie cups, etc.) for solvents with closed UL-approved containers. 2. Maintain closer surveillance of existing local exhaust systems, particularly at No. 1 printer, to Insure their optimum operation to prevent the escape of solvent vapors into the work area. Hot air blasts should not be allowed to exceed exhaust capacity. Dust Abatement Recommendations 3, 5 and 6 under Vinyl Chloride Abatement will significantly reduce exposure in the blender area. In addition, the following arc proposed: 1. Improve maintenance of feeders over Line 1000 banburys to prevent material leakage. 2. Eliminate blow-back from Lines 2000 and 3000 trim cyclones. 3. Install a ventilated booth for weighups on the blender floor, similar to that provided f r color dispersions. Page 4 ucc 067992 Dust Abatement (Continued) 4. Install a more effective dust collecting system for the north mixer station In the foam mixing room. 5. Institute special precautions with the use of powdered lead or other toxic compounds, Including mandatory wearing of approved respirators. Ventilation See Reconmendatlons 2, 3, 5 and 6 under Vinyl Chloride Abatement and Reconmendations 3 and 4 under Dust Abatement. Local ventilation on the blenders appears to be the key to avoiding contamination of the working environment with vinyl chloride released in the blenders. This will become even more critical if and when the present emergency standard is lowered in the direction of "zero tolerance." Noise Abatement Line 2000 FCM gear reducer should be posted to limit exposure without ear protection to three hours, and the area north of Line 3000 FCM posted for' a six hour limit. The in-line trim cutter should be further sound-proofed for a 5 dBA attenuation. Lighting Provide additional lighting in the blender area, blender panel boards, ware house areas, shower room and lunch room as outlined under Discussion. DISCUSSION Test Methods Vinyl Chloride; Temporary TLV*50 ppm (ceiling limit, no TWA). Vinyl Chloride is collected according to CAP Method 38C-9C1-R2, drawing a measured amount of air through a glass tube packed with activated charcoal. Any organic vapors are adsorbed on the charcoal, and later desorbed in the laboratory with carbondisulfide. The extract is then analyzed by gas chromatography. The procedure Is designed for four hours of continuous monitoring at a flow rate of 28 ml. per minute. Since such long-term sampling does not detect excursions of short duration, certain tasks with higher potential of exposure were monitored at rates up to 115 ml. per minute for short periods in order to obtain a sample of sufficient quantity to measure. This method has greater accuracy than that used by OSHA which uses commercial charcoal tubes having only 20% of the capacity of the especially prepared UCC/C&P tubes. Smnples taken during this survey were analyzed by the CAP Environmental Health Lab at the South Charleston Technical Center. The Miran I portable Infrared gas analyzer which proved useful for continuous area air monitoring at the South Charleston plant was borrowed during the week Page 5 * UCC 067993 Test Methods Vinyl Chloride (Continued) of June 17 from the C&P Environmental Health Lab for vinyl chloride monitoring. It proved helpful in confirming that some areas not completely monitored by the charcoal tube method were low in vinyl chloride, but interference at the 10.7 micran wavelength was encountered when monitoring process equipment such as the blenders, mixers and extruders. The Interference was traced to non-descript hydrocarbon solvents introduced into the preblend with the stabilizer, causing the Miron X to read higher-than-actual vinyl chloride concentrations. These "mineral spirits" rule out the use of total hydrocarbon analyzers such as the Century Organic Vapor Analyzer. TCA instruments can provide on-the-spot assurance, however, of safe vinyl chloride levels if their total readings, after correcting for vinyl chloride, read under the allowable 50 ppm limit. Instrument noise encountered with the Miran I renders it' unreliable for vinyl chloride measurements under 1 ppm. Solvent Vapors: TLV - See Table, Page 9. Organic solvent vapors are collected according to C&P Method 38C-8A2-Ra, similar to the method for vinyl chloride but using smaller carbon tubes. Complete analysis of all hydrocarbons collected is made by gas chromatography and the data used to calculate micro-grams per cubic meter of air and ultimately, the dosage. Since there are no restrictive celling limits on the solvents in use, exposure is best measured by personnel sampling over longer time periods. However, for purposes of control by locating the main sources of contamination, the Century Organic Vapor Analyzer is used to provide on-the-sport direct readings of total hydrocarbons based on 100% response to methane In air. Dust: TLV - 15mg/M^ for Total Inert Dust. C&P Method 38C-10X2-R2.4 is used for measuring total airborne dust by gravimetric analysis. A measured stream of the sample air is drawn through a preweighted PVC membrane filter by means of a battery-operated personal monitoring pump (MSA Model G) carried by the operator. After vacuum drying, the filter is reweighed to yield a measure of the dust concentration. Noise: TLV - 8 hours at 90 dBA, with a 50% reduction in time allowed for every increase of 5 dBA. A Model 2209 Bruel and Kjaer imp1use precision sound level meter was used to measure sound pressure levels from noticeable noise sources. Lighting: ANSI Specification All.1-1965 (R 1970) in lieu of 0SHA specifications. For Chemical and Rubber Manufacturing: 30 ft-candlea Toilets and Washrooms 30 " Panel Boards : 50 " Light intensities were measured with a Weston "Photronie" meter. Radiation: Code of Federal Regulations, Title 10, Part 20. Maxima allowable leakage - 0.005 microcuries. Wipe tests are conducted by Industrial Nucleonics Corporation on a contract basis. Ventilation: As required to limit air contaminants to concentrations listed under Subpart G, Section 1910.93. Air velocities were measured with an Alnor Jr. Velometer. Page 6 ucc 067994 Vinyl Chloride - See Appendix, Table 1 The scheduling- of the Vinyl Fabrics Division survey to coincide with the mandatory monitoring specified in the OSHA emergency standard afforded an excellent opportu nity to thoroughly examine the effects of the new regulation on Bound Brook opera tions with a minimum of delay and effort. These effects were not fully anticipated at the outset, the general concensus being that the new regulation was mainly directed at the VC chemical and PVC polymerizing plants rather than the downstream fabrication plants. However, detection of up to 9700 ppm VC in the air space of a van box loaded with QSAN resin clearly demonstrated the presence of VC at Bound Brook and the need to control any further release of VC In downstream operations. The high level of VC would be expected since a typical load of 40,000 pounds of PVC resin with a residual monomer content of 0.2% contains 80 pounds of VC- Zf only 1% of this diffuses into the air space above the resin, assuming the air volume to be 20% of the volume of the box, or (0.2)(1900^ * 380 . cu. ft., the 0.8 pounds of VC entering the air could amount to /0.8 lb. )59 cu. ft. \J>2.5 mw lb-mol conditions. 380 cu. ft Some dilution of these high concentrations can be expected as the box is emptied, but proper precautionary procedures for safe entry should be followed by'personnel prior to entering for cleaning or repair. However, there is presently no such occasion for entry at Bound Brook. If the portion of OSHA's May 10 proposed "zero" tolerance standard specifying labelling becomes law which is expected, van boxes of PVC resin will probably be treated as containers of VC, requiring the posting of consplclous warning signs. Refilling empty containers may also require the restriction of VC emission from the atmosphere if EPA imposes tight regulations. In contrast, personnel who connect the van box outlets to the alrveyors experience exposure of only up to 2 ppm. Evidently the hook-up procedure of inserting th rubber spout into the alrveyor inlet confines the resin within essentially a closed system, while the operator breathea fresh air from outdoors. Although there are usually visable accumulations of resin dust in the airveyor shed (Bldg. 102) any residual VC evolving therefrom is evidently highly diluted by the high volume of naturally-circulated ambient air. The next evolution of appreciable quantities of VC measuring up to 4450 ppm occurs In the ribbon blenders, probably accelerated by the heating and agitation. An existing ventilation system connecting all eleven blenders to a dust collector and exhaust fan was designed to abate dusting during the gravity feed of resin to the blenders and the charging of liquids. However, during the survey, this "Trans Vair" system was Inoperative due to pluggage. As a result, sufficient VC evidently contaminated the air during charging operations to raise the level in the ambient air on the blender floor to 7 ppm. During the week of May 13 the ventilation system was cleaned out and reactivated, but No. 3 blender on Line 3000 and Nos. 1 and 3 on Line 2000 received little or no vacuum from the system due to misalignment of connections causing the flexible connecting sleeves to constrict and pinch off air flow. These misalignments have since been corrected so that all eleven blenders are properly connected to the vent system. The Importance of ventilation on the blenders as a prime means of abating exposure of perators to VC was demonstrated by measurements taken while the blenders wer IJCC 067995 Test Results - Vinyl Chloride (Continued) being manually charged without benefit of ventilation. Escape of VC bearing fumes into the breathing zone of the operator was evidenced by values of up to 46 ppm VC for on-the-man samples during bag-dumping. Subsequent teBts taken with the local exhaust system operating were substantially reduced, one measurement being under 1 ppm. Although the vent system automatically vents each blender during the charging cycle, thereby protecting the operator by draining air inward through the charging hatch rather than releasing fumes Into the room, there Is n such protection to operators when they reach Into the blenders to scoop samples of preblend for color-checking. This is done after about 45 minutes of blending after the air confined within the head space has picked up VC from the heated and tumbled resin. The high levels of VC in the airspace of closed blenders, and lack of negative pressure In the blenders, caused high excursions of up to 175 ppm measured while operators sampled unventllated blenders. Although the time required to scoop a sample of preblend is less than a minute, the fact that the operator's face is so close to the hatch opening accounts for the excursions measured. The total exposure from the excursions is probably less than three minutes per eight hour shift, considering that each sampling of preblend takes less than 20 seconds, and no more than eight blenders are sampled by any one operator. While considering the high excursion levels measured for short time periods, it is important to note the significance of selecting the time span for testing. Present OSHA monitoring procedures call for a ten-minute sampling period at a rate of 100 ml/mi11* Under such conditions, a short-lived excursion of less than a minute would not be detected, and the integration with time which occurs during such sampling, could result in an average level well within the present limit of 50 ppm. This is apparent if we assume a likely profile of VC levels and calculate the time-weighted average according to the following plot, assuming an initial level of 180 ppm for the first 20 seconds the blender hatch is opened, and an average of 90 ppm while the level decays after the hatch is closed for the next 40 seconds, and an ambient level of 6 ppm In the blender area. The ten-minute time-weighted average (TWA) would be given by: (20 secA 140 sec A 60 / (180 ppm) 4- V 60 J 90 ppm + (9 min.) (6 PtmO " 60+60+54 " 17.4 ppm 10 .IQ-- There is, however, the possibility that OSHA might revert to the NIOSH "grab" sample method of monitoring, in which ease an air sample could be collected in less than one minute during the time of the excursion, and thereby Indicate a violation of the 50 ppm ceiling limit. It is for this reason. In addition to detecting excursions in order to design abatement measures, that the short term samples were taken. As a preliminary safeguard, the blender operators have been provided with longhandled scoops which permit the withdrawal of material from blenders at a safer distance from the hatch opening. In addition, the operating department is planning to provide manual controls for the vent valves which will permit the operator to place a blender under the reduced pressure of the exhaust systen pri r to opening the blender hatch for sampling. This should afford complete Page 8 UCC 067996 Test Results - Vinyl Chloride (Continued) protection to the operator and serve to lower the VC present in the ambient air of the building. Exposure of personnel downstream from the blenders appears minimal, evidently no higher than 1.4 ppm. This would be expected from the high volatility of VC and the extensive high temperature and mechanical working received in the mixers, extruders and calenders, which tends to strip out volatiles, exhausting them through the roof vents. Tests conducted in the foam operation indicated negligible exposure to VC under 1 ppm. This is probably due to the use of dispersion-type resins low in residual monomer as compared with suspension resins. Tests of the Bay 15 in Building 101 operation indicated no levels above 1 ppm on the first floor including the banbury operator, and only an excursion to 5 ppm at the blender while the operator added colorants through a small hatch. However, exposure may be greater during bag-dumping since no ventilation is provided. Solvent Vapors - See Appendix, Table 2 Operators in the printer and ink preparation areas have chronically expressed concern over the levels of solvents in the air, largely due to the low odor threshold values of the solvents used which tends to emphasise their presence even at safe low levels. Fears were exacerbated by the cases of peripheral neuropathy reported out of the Columbus Coated Products episode involving MBK and MIBK. Previous monitoring in the printer and ink room areas was done by the Century Organic Vapor Analyser, a useful direct-reading instrument for hydro carbons. This is very effective for locating sources of emissions and measuring total hydrocarbons. Its limitation is lack of identification capability; one must know by other means what particular hydrocarbon is present in order to determine actual PPM. Moreover, the Centruy OVA is not adaptable as a dosimeter for personnel monitoring. Therefore for the first time at Bound Brook, charcoal tubes worn by operators were used to accurately measure exposure of operators working in the solvent areas. The measurements reported herein were taken in February in anticipation of an inspection by a Hew Jersey Department of Labor Industrial Hygienist as the result of an employee complaint. The charcoal tube method was selected as the most effective means of monitoring and considered superior or at least equal to any method expected to be used by the State Hygienist. A State inspection was actually made a month later, the Industrial Hygienist using a J&W Model SS-P combustible gas detector rather than charcoal tubes. The reason given for not using charcoal tubes was the lack of analytical personnel. Readings on the J&W PPM scale were considered satisfactory by the State Hygienist, hence there was no need to submit our charcoal tube findings. We would, however, expect OSHA to use the charcoal method instead of the J&W "sniffer" which has insufficient sensitivity in the 0 to 200 ppm range. The principal solvents in use during the monitoring, plus MBK used at Borden's Columbus Coated Products, are listed below with pertinent data: Methyl ethyl ketone (MEK) or 2-Butanone *Methyl butyl ketone (MBK) or 2-Hexanone Methyl isobutyl ketone (MIBK) or Hexone Tetrahydrofuran (THF) 2-Nitropropane (2-NP) *Hot used at Bound Brook. Page 9 TLV PPM n*/MJ 200 590 100 410 100 410 200 590 25 90 VP @ 20C MM 70 2.6 15 138 13 BP @ 760MM C 80 127 116 65 120 ucc 067997 Test Results - Solvent Vapor* (Continued) MEK and THP, being the more volatile of these solvents, readily generate odiferous vapors locally and are therefore subject to complaint if operators get too close to containers. Fortunately, these have the highest TLVs. MIBK, having low odor threshold level, is quite noticeable. Moreover, Its nomenclature is often confused with the MBK associated with the Bordon problem. The low volatility of the more toxic 2-NP renders it a minor factor in the working environment. An appreciation for how these solvents contribute to the overall dosage can be seen by reference to the Appendix, Table 2, which lists the amounts of the various solvents collected from the air on charcoal. Although MEK and MIBK are generally used on a 50-50 weight basis is the No. 1 Printer, the amounts evaporated into the air are roughly in proportion to their vapor pressures, resulting In consider ably lower concentrations of the more toxic MIBK than the less toxic MEK., The chief operator's Intake analyzed in the ratio of 151 MEK to 29 MIBK (mg/MJ) while the relief operator performing similar tasks analysed 185 MEK to 37 MIBK. Actual exposure is calculated from the chromatagraphic analysis of the sample, taking into consideration the amount of each component and its ratio to the TLV for the maximum dosage allowed for eight hours. Using the general formula for calculating dosage: + -Hz 1 For Maximum Permitted dosage for n number of components. C * Actual Measured Concentration (mg/MJ) T TLV Concentration (mg/M3) The dosage Imparted by each of the four components is calculated in the last columns of Table 2. It Is worthy of note that these solvents have no celling limits, therefore there is no need to test for excursions and long sampling times are quite proper for determining exposure. Nevertheless, it is Important to periodically monitor the printers with the direct-reading Century to maintain control of solvent vapors in the working environment. Certain sonas within the printers yield measurements in the 100-300 ppm range as followsj Inside Mu. 1 Printer, between lull ft(al1me 2 and 1 inside Mu. I printer, between ink HLet!on* 1 and Unwinder Inside No.3 Printer, between Ink Stations l sud % Inside No.3 Printer, between Ink Stations 3 and 4 Outside No. 3 Printer, between No. 1 and 2 Ink Pots Although the chief and relief operators frequent these zones in which the air may contain contaminants above the TLV, time studies Indicate they spend less than half their time in such areas. This is confirmed by the charcoal monitoring results of 0.40 to 0.50 (40 to 50%) of allowable dosage. The other members of the printer crews were not tested since their tasks do not Involve handling solvents, their time being spent in the wind-up and packing areas away from the solvent fumes. The strike-off day shift operator appeared to have the greatest exposure of 70%, probably due to a particularly active day of color matching and frequent cleaning with solvents. The ink coordinator, in preparing nixes in the ink room where area smiling indicated 67 to 92% dosage, analysed only 53% allowable exposure. The area sasiples are representative of extreme conditions in the ink row, having been taken in a poorly-ventilated corner near the Oowles mixers. Page 10 ucc 067998 Dust - See Appendix, Table 3 Dust monitoring was conducted in the two areas of greater concern to personnel: the blender mezzanine and the foam line mix room. Dusting appeared highest during the charging of resin and fillers into the blenders, there being no ventilation on the blenders during monitoring. Dusting was particularly severe in the area of.the Line 1000 blenders which were being charged largely by hand dumping QYNA resin. Even with the highly vlsable releases of-dust, all long term samplings analyzed in an acceptable range of 2 to 7 mg/IT. With no celling limit on dust exposure, there are no violations from the excursions which occur during charging. However, such excursions, one of which was measured at 170 mg/M3 during the hand-dumping of QYNA, create a housekeeping problem and concern on the part of employees. This source of dusting is effectively eliminated when the blender is connected to a vacuum source such as the Trans-Vair blender exhaust system. When this system is operating effectively, the capture velocity at the open blender hatch exceeds 100 fpm, thereby conforming to the control velocity specified in the State of Mew Jersey Department of Labor Chapter 122, Exhaust Systems (proposed). Other sources of dust observed during the survey were leaks from the Line 1000 overhead feed system. There were dust emissions from the skip hoist dumping location where a side plate had been removed and there was no exhaust due to the Dynaclone dust collector system being down. Considerable leakage occurred from the screw conveyor feeding the banburys. Other principal sources were the hoppers of Lines 2000 and 3000 FGMs where blow-back of preblend occurred due to a high flow of air from the trim recycle cyclones. Dusting in the foam mix room was highly vlsable during bag-dumping of resin at the mixing stations. However, on-the-man samplings taken during bag-dumping gave values within limits. Dusting at the foam mixer (south station) measured lower at 5 mg/M3 than that at the skin mixer (north station) which measured 18 mg/M3 during 15 minutes of bag-dumping. However, this averages to a much lower level when time away from the dust emission is added. Nevertheless, improvement is recommended for this station where ventilation system for the mixers produces visable emissions from the roof exhaust fan, evidently due to resin by-passing the filters in the entrance chambers. This will require correction for compliance with EPA requirements. During monitoring in the blender charging area, several operators expressed concern over the use of Cab-O-Sll, a particularly light and dusty powder. Vendor's data indicates this to be amorphous, containing no toxic crystalline silica. The problem from breathing the dust is Its high affinity for moisture, causing drying the of throat If Inhaled. Another concern pertained to the weigh-up and handling of toxic powders. None were seen in use during monitoring, but a pallet load of "Dyphos", dibasic lead phthalate, was noticed on the blender floor. It was explained that this was used for a short run of a customer's formula, and may not be run again. If necessary to use such material, approved (Dustfoe) respirators should be required during handling, full ventilation should be available at the charge point, and the formula should be adjusted to permit the use of full weight bags rather than requiring weigh-ups. Noise No noise levels above 90 dBA were measured in any operating areas. High levels were measured in the immediate vicinity of the FCM drives and the Line 1000 on line trim blower enclosure. Sound pressure levels are as follows: Page 11 ucc 067999 Noise (Continued) Item Location Allowable dBA Time. Hrs, Line 1000 1 Within .two feet of trim blower enclosure in aisle between L-1000 and L-2000 calenders 2 Two feet west of lower calender roll 3 Foot of stairway to calender 4 Aisle between cooling rolls and take-off 86-95 88 87 87 4 8 8 8 Line 2000 5 Directly below inlet to trim cutter housing 6 Within one foot of FCM gear drive 85 8 97 3 Line 3000 7 Between FCM and panel, north of drive 91 6 8 Hydrotherm blowers, within one foot Motor-Generator Room 88 92-99 8 2* * Already Posted Items 1, 6 and 7 require posting of signs reading "CAUTION - EAR PROTECTION MUST BE WORN WHEN WORKING IN THIS AREA FOR MORE THAN _____ HOURS PER DAY." Since Item 1 is on the "fringe" of the take-off area, it is reconraended that damping material be added to the enclosure and conveying lines in order to reduce noise levels below 90 dBA. Ventilation openings may have to be closed or baffled to achieve sufficient noise reduction. Lighting Lighting in most operating areas is above standard with the exception of the blender floor where Intensity along the main aisle between the panel boards and blender charge hatches measures as low as 3 ft-cdl. Lowering the upper fluorescent fixtures or installing local lighting would improve illumination in this busy area. The panels are in need of local lighting to facilitate reading controls and indicators. Local lighting is reconraended for the log table to increase illunination from 3 ft-cdl. to 50 to improve readlbility of work sheets. Warehouse areas are minimal, largely due to lights no longer centering on aisles. The east warehouse foam roll storage racks are in need of better Illunination measuring 1 ft-cdl. along the C and E racks. Lights obscured by these racks should be centered over the aisles between D and E racks and c and CC racks. A minimum of 5 ft-cdl. should be available, with 10 being desirable. A similar situation applies to the storage area for the embossing rolls. Illumination In the main men's room area ranges between two extremes: 125-150 ft-cdl. in the lavatory-toilet room versus ANSI standard of 30 ft-edl. and 3 ftcdl. in the shower room. Better lighting is therefore recooraended to bring the level up to 30 ft-cdl. in the shower room and drying area. The locker room is satisfactory. Lighting in the lunch room measured in the 3-5 ft-cdl. range. An improvement to 10 ft-cdl. is reconraended. Page 12 ucc 068000 Radiation - See Appendix, Table 4 Result* of th last semi-annual inspection f March 19, 1974 by Industrial Nucleonics Corporation are reported. Page 13 UCC 068001 APP{NOlx Vinyl Chloripf F<^' 1. - Blp&- lor jTtATTZbt r IV y 5*TAfvi>AC />.' PRQPoS&V 0 PPM A Ax. ^ "No de-tec^/yUle - ? ero A p p e n O ix : ucc 068002 Page 14 I LOOltlOM OB J0 HimO APFWDIX, TUU 1 nsoffs of curcoal TV** sjwnin aid akaltsis for vim chloriti SAIffLXXO Tine Rat* Saapla Volane Vinyl Chlor&A* In. al/eln_____________ Lltra__________ --_____ WR Air apace la na Vox loaAet with (0A1> Plant 1<0J Air iptti In tu box lo*4*4 with QSAl, UmI W Air apae* la na box loaAet with 9AI, Plant 9027 L-l planter 1--tfately after eharplnp QUA b-2 hlaaAar after bleotlnp of QUI, plaatlolaera, eta. Irl llanAer after eharplng 09Al, before plaatlelaera. etc. b-2 planter after eberelax Q)AI, before plaatlelaera, t*. b-3 Plantar panel heart area PIAX- 101, Pay 19 blenter area PUp. 101, Pay 15. baafewry Alaeharpa Bynaelone exhaeat (want fran trl banbeiy) b-2 fret! ant feet to FCR 1ft PGK Alaeharpa If3 MM Alaeharpa lrt Pxhauat fren Moyle extrwter hopper b 1 Pahaeat fron Moyle extreAer hopper b-2 piaoharpo fren Moyle extrwter Ale Mear of If3 Oetenter roll* t-t Catenter ataok exhaaat b-2 0*1 enter anhocalnp roll* 66 30.5 52 31 30 32 Jb 30 77 31 3b 33 20 31 138 31 20 87 3b 77 127 31 10b 30 120 33 12 110 210 33 11 110 125 33 10 100 60 28 85 30 2.02 1.61 0.96 1.02 2.38 1.12 0.62 b.27 1.7b 2.62 3.9b 3.12 3.96 1.32 6.91 1.21 b.13 1.00 1.68 2.55 8boo 9700 71b 292 90 27000 35 bbbfl 7180 25lb 3191 2017 78 7.2 5.7 0.75 1.3 0.1 18 1.8 7-3 0.9 6.0 0.6 9.0 106 2.7 6.0 1.1 0.35 9.0 0.85 1.9 2b 0.7b 5.6 13.5 2.1 Realn Alrwayor Operator ooaneetlnp wan box lo. 657 of QBAP Resin Alrweyor Operator coonoetlnp wan box Bo. 607 of 03AB b 30 2.1 85 0.12 0.18 0.6 1.98 < 1.8 < 3.9 ucc 068003 Page 15 APPSWm, TABU 1 (eont.) LOCATIOB OR JOB FO0RIOR L-3 Mentor operator IpZ Mentor Operator L-l Blenier Operator L-2 BlenAor operator. barging MenAer L-3 BlenAor Operator, charging blenier L-3 BlonAer Operator L-3 MonAor Operator, oberglng blenier L-2 MenAer Oporotor, oberglng blenier L-l MonAor Operetar. oberglng blonior L-3 MonAor Operator, oberglng MenAer, (blonior rente*) L-2 Monger Operator, oberglng blonior, (blonior oentei) Bap 13 Monier Operator, charging blenier Bap 13 Banbourp Operator Bap 13 Oalenier Operator L-2 Calenier Operator L-3 Caleniar Operator L-2 Calenier Operator L-l Colonger operator L 1 Monger Operator, oonpllng blenier L-l Blenier Operator, eaapllng blenier L-2 Blooiier Operator, eanpllng blonior L-2 Blenier Operator, eaapllng blonior L-3 Blenier Operator, eaapllng blenier L-3 Blenier operator, peopling blonior Blenier Operator, roll-ellllng aapplo of probloni Monier operator, roll-allllng eaaple of probloni Peon Line, Skin Riser Boon Line, Bean Miser Bap lo, BHig. 101, Probloni Operator, charging tote bln Bap 10, Mig, 101, Probloni Operator, oberglng Bap 7 blonior Bap 10, Mig. 101, Mil Operator SAHPLira Tina Rato In. el/nln 152 183 173 3.5 3.3 96 11.5 2.8 9-7 3.5 b.o 2.0 35 38 152 155 1*8 3* *.5 1.0 1.0 0.5 1.0 1.0 5.0 *.0 19 15.9 19 8 3 31 30 30 31 31 30 30 32 90 105 115 85 105 71 32 30 30 81 82 105 105 95 105 105 105 108 30 30 9 105 85 Saaple Tolona Lltere 5.*6 5.50 5.19 0.108 0.103 2.88 0.3*5 0.09 0.87 0.368 0.*60 0.170 3.68 2.70 i.96 *.65 *.** 2.76 0.37 0.105 0.105 0.0*75 0.105 0.105 0.525 0.*32 0.56 0.*8 1.71 0.8* 2.55 Tlnpl Chlorlia Bern PPM 90 90 37-5 2.5 1.0 19-8 *5 5.1 101.7 < 0.9 11.9 2.3 < 1.8 < 1.8 13.5 8.1 2.7 *.l 165 1.7 *.l 3.* 29.* 3* .5 < 0.8 <0.8 ^1.5 0.6 < 0.6 < 0.6 0.6 6.5 6.* 2.8 9.1 3.8 2.7 5.1 22.2 *5.8 < 0.9 10.1 5.2 < 0.2 <0.3 1.1 0.7 0.2 0.6 175 6.3 15.3 28.1 110 129 < 0.6 < 0.7 < 1.1 0.5 <0.1* <0.28 0.1 ucc 068004 Page 16 i or oumou moon, nui z 3ARTURO AID ANALTS IS POR SOLTWT VAPORS nr o. 1 Printer Chief Operator - D. R. Relief Operator - 3. 0. o. 3 Printer Chief Operator - 1. A. Relief Operator - I. 3. Strike-Off Operator - P. T. ink coordinator - V. ink Roon (Area) Ink Room (Area) SPL TIM In. Rate al/aln It2 lOt 106 66 113 115 116 120 10t 95 U7 120 9* 80 ita 115 Seaple Toleee Liters RII pa mt/fP 590 111 3 K a/*3 tio T RP 590 2-n M mg/wP 90 Calealatlon of Soaapae m KIRK TIP 2-IP Tort It.6 9.6 2290 151 1770 185 13.0 13.9 9-9 lt.O 7.5 16.6 2150 166 22tO 161 1190 120 2t50 l?t 1600 2It 7t06 tt7 t25 29 1060 72 70 5 350 37 270 28 <to k to 3 130 10 <to <3 to 3 870 63 70 5 1290 130 780 79 <to <t 130 9 ltto 103 60 t 175 23 930 12k <to *5 230 It 113t 68 < to <* 121 + *2 + 21 + _2 - 0.50 590 tio 590 90 12 + _21 + + -i - o.t; 590 tio 590 90 ! + _1 + -IS + JL 390 tio 590 90 Mi + _2 + _2 590 tio 590 90 l*o 12 _I2 _* . 390 tio 590 90 m+ 9 + m + A. 590 flo 590 90 m + _*i + im -2 590 tio 590 90 m. j* . _+ _*. 590 tio 590 90 M .5* 7* .5: .6 9 ucc 068005 Page 17 ooocSs r^Oci CD APT8ICDIX, TABU 3 memos or ofuviMTflic ahalts is for hbsih dust SAnmtM Air SMplo Tlat Roto Vol, Bright In. al/alnUttnHg.ng/H^ b-1 BlonAor ogntor, mIi mil wl^t-ifi, no BlonAor charging L-2 Unlir ogntgr, 2 BlonAor charges, minimal b*g-*usplng L-3 BlonAor tpintor, 2 BlonAor ihtrpi, aoAorsta tti-taplnt Log table. Uingr mi., (Atm saople) L-l BlonAor operator, puopoA K} bags QW into BlonAor Irl BlonAor operator, AuopoA 7 tap of fillers, i bog CsbOSll, 2 aolgb tap L-l BlonAor oporofeor, proporoA 5 Mlp bags of Out, AIMS. oaA ohorpoA 1 BlonAor Above soaplings *ore noAo without vontllotlon on blowAors. 103 1650 128 1690 103 1600 150 1600 10 1675 12 1750 75 1750 170 216 165 2*0 16.75 , 21 131 9&0 810 920 560 28b 125 870 5-8 3.B 5.6 2.3 170 60 6.6 FOAM UBt "Skln'nixori noAo 2 alxos, Auaplng 11 bogs of Morrinol rosin snA 5 bops of Fllovlc Into oaeh "Pom" aloof; AwneA 22 boos of OTJTIiA W.9 22,0 1725 1700 25.7 _______21-* *70 18.3 190 _______ ill Page 18 t* FIELD WIPE TEST REPORT API >1X, *TABLE 4 {Long rm) la Customer A/<j / c aJ C'e* A? /?_____________________ _ lb Address ' < i^. aA ^ * Due Date 1 c Id le z 3 4 5 6a 6b i-------7 Lib HS'o-uiSrc-ejSN'o. S~3&1-t S-Jc 7-T ts'--usspy-jtt'jUS-X tS-Jlot 'i-tia" J7 .? , ,.4s~ Frame No 046* l/A i odirtns rx>;>4h 6jJ?4il/f7#9 coe>4u/t/f*x4 6,4?* 3ZZ/7J/49. sztA'/z^Zn Gauge No. eitsi/i/t ccto4iil)i4JOtVt H*c?*iLk*3>4/4WP*7V\1 Cc?t iscHco# AASS aCa/Z Labels &4AC. tC,XK C*. 0c/.C*- stJL zxa 0S6 . W. T. /S//f MAaA/Y/'/-{C/fi A//! Ms*/?'f ju<e i4/Z/iff y*rj/t?irff}J S!iutt ( At/fc CcA/Lttt-C 4/4Cf** -* t 4wr alrA*m4r/z r 0/CIndies. cSC *t i-<AAv,KCtr . y*# < i aT/ekstABy/t ihtAkjidQzAt. 'tIstMm-t-i yfcSlfA^ 'it/A-s* /A kZjd/L wMsAwI/.:L/yIMijLmi-,-\ Date 3fa/7i 3/fif?\/ 3/Hfi SJffrrttfhlil sfflh/ 3/rtfrf phi >lf/"/ojz*/r//?*y?rt/// Remarks CCt*'&i-*44 DiOf/t*P>f/ /h-/'.*.yr-ji~/AA/*'*?f**-*. /yf&S^rfetv/Z?- I\ /fs fjSf xr </{" A*r S~ />i /~UcJ*s?ef /'< . // 7Q3t 'tJXt /<. j~ A7.f^e As'&*<<?' Ao tr&ftA/sSJ?/>/f//AA33A~$?/ssSA/s*ZjXsfsr^ffffZtAy-,Jjj^ *l ZH>0i(;ttef3.-7#SSeTXZ"p*-Mr'l/tSf/lt'.rA&tZr?i^f)/f)\i Test M.-ct: . -i fr i-4- rL/vrj.?r Sr&* Asf vr. 'a As /? Af'** Sts ;.?tfd AA** . >, fAr "1 // A. . '' </, 'XfZ V/ */J< S3s-t. Zsi S&f Q,a/sCS<s <ASc V. ' __ AA.4HAz/&sss2i '* A, s r- '**.* / s* tsfs/?< tf A/*fi/tcL/se'-.//ssS*, r/i^vy5 /& ASiA.S jk St, /2i/j> sAt/ *> <X-CAAe_t*_r*AXTr~S4s>S*ssr7*S.C/-Z/,fA^S,^J/AMS*'SAS&s,>tSsy>Y^Zs-_s_AjtI_j!_____ \1\ &./ZcS*' 1f j ! 1t ucc 068007 _J_______ i "BF-145 (4-18-73) / Page 19 Installation Supervisor: ACKNOWLEDGEMENTS The execution of this survey was particularly facilitated through the unlimited cooperation of the following individuals: Operations: j. Kerman, H. Koenig, S. Molnar, M. Shvidrik, W. Westcott, P. Wick and T. Zambo, Production Supervisors Analytical Service: J. Cavender, G. Hurley and J. Heff, Chemicals and Plastics Environmental Health Lab, South Charleston; Safety and Environmental Protection; R. E. Rosfjord Page 20 ucc 068008 ucc 068009 T DISTRIBUTION Mr. J. D. Baker - BB Mr. R. A. DeCoudres - BB Mr. L. F. Doyle BB Mr. J. L. Goodson/Shlft Superintendent* - BB Mr. F. Granger- BB Mr. N. H. Ketcham - SCTC Mr. F. J. McCarthy - Chicago Dr. C. S. McKinley - BB Mr. R. E. Peele/R. R. Greebert - SCTC Mr. E. B. Sharp/F. L. Hlegleb - BB Dr. A. B. Steele - NY-28 Mr. R, N. Wheeler - SC Mr. D. L. Wiley - NY-21 RECEIVED JUL 24 1974 R- N. WHEELER, jR ucc 068010