Document 3kYbxxOvBYgzqXaaeE8Kr446

FILE NAME: Union Carbide (UC) DATE: 1963 Oct 23 DOC#: UC188 DOCUMENT DESCRIPTION: Internal Memo RE Insulation Block Dust Survey Construction Insulation Shop Plant with Report CUANRIBOIDNE 1 internal oonmKmr'OMDKNOM UNION C A R a iO K C H E M IC A L S C O M P A N Y r . p w Mr. s. C. Giambruno Cm^--r M*l** Industrial Relations Kirnim rur a m ^ 23 October 1963 D epart - Plant Sli Cnrk Mr. L. N. Dickinson Mr. N. S. Eastman Mr. R. A. Huber Mr. B. F. King Dr. E. M. Best r C. U. Dernehl Mr. J. W. Mr. p. E. Insulation Block Dust Survey Mr. R. A. Mr. D. R. Construction Insulation Shop -- . Plant sn * Mr. N. H. Mr. L. BB.. Weddell - Safety Dept. 1th? po^ts out S i S t i l l S 2 t5 S ! ion Larey-Tenp' insulation blocks cannrrt- frr!. ely that Thermobestos" and these to me. ^ ***** *** m y connents. suggestions or criticism, please direct RJS:hl Enclosures S - jY~?? 04862 . INDUSTRIAL HYGIENE SURVEY Construction Insulation Shop - Building 511-2018 Report 63-IH-3-G-1 SUNDRY: The Construction Insulation Shop (Building 2018), Plant 512 location, routinely fabricates _large quantities of insulation block with ventilated band saws. Thus none efficient procedure of fabrication has replaced an older, tire honored, practice of using simple handsaws to do the job. However, it has, at the sare tire, created a health hazard resulting from exposure to excessive concentrations or atmospheric dust. hazard to health has been evaluated and reported previously* with the resultthat: one material, "Thermobestos" was clearly identified with the r S S ? n iifSfdel ! LV> and^another terial, "Kaylo", was safe to fabricate (within TLV). The present report (the third on this subject) was initiated in an attenpt to supply answers to three basic questions; (1) was there any error in the original evaluation of "Kaylo", (2) can supplementary exhaust ventilation reduce the Thermobestos' hazard to within safe acceptable limits, and (3) is t0 heaIth Produced in the fabrication of a third material, i.e., "Carey- - . r ^ information uncovered in the present evaluation reveals the following facts: ^ , 1. "Kaylo" insulation blocks can be safely fabricated with the existing equipment. 2. Thermobestos" insulation blocks cannot be safely fabricated at the present tire with existing equipment, but could be safely fabricated if the exhaust ventilation is improved. 3. The TLV (Threshold Limit Value) for "Carey-Temp" is identical vath that established for both "Kaylo" and "Thermobestos", i.e., 20 mppcf (million particles per cubic foot) of air. 4. "Carey-Temp" also cannot be safely fabricated with the existing equipment, but could be if improvements are rede in the ventilation system. 5. The original downdraft" exhaust ventilation rates, on either band saw, do not meet the recommended capture velocity rate of 4,000 fpm (feet per minute). 6. The supplementary "overhead" exhaust ventilation on both band saws, is an improvement and the rates do meet the recommended capture velocity rate of 4,000 fpm. I.H. Reports 62-IH-l-G-l"ah3 62-IH-2-G-1 A0 48 6 3 2. I ^ O D U C n M : A ^ P ^ , submitted in torch 1962, stated that an inhalation hazard to health was produced in the Construction Insulation Shop whenever ''Thernobestos" ^ July 1962. second survey w condSted in order to evaluate three new Theimobestos" materials which had been supplied by^he nanufaether for evaluation. This svhvey revealed that, although the " ' Siir+h f vfT 1 t0 healtt_had substantially reduced f*om that encountered f S d L t i L fS>,SUrVey* 2 * atTOSPheric dust concentrations being emitted during * th?" were still in excess of the Threshold Limit ZSjf Therefore, all recomnendations should remain exactly as stated in the initial report of March 1962. , __, . . , r^ 6 manu^ac^urer'ar>d Union Carbide's Purchasing Deparorent expressed . s great deal of concern about the findings revealed in this imtialreport when it was uncovered that the manufacturer's Research Department also tod evaluated these materials and vas not able to produce results comparable with those contained in the report of torch 1962. That is to say/tto atnospherS dust S S t o t i m 1hi1^ r POrted byKthe manufacturer* '***' processing "TheLitestos" irtsulation blocks, were substantially higher than those revealed in Report ^ revelation disclosed the need for a more extensive evaluation + aS t0 r^^olve,a11 differences of opinion relative to the atmospheric dust exposures in this environment. nr T ^ decision in favor of further evaluation, promoted the production of a much more extensive study than was originally planned, a study ^ ^ a i S i UalS f enCOn??SSfd three Separate Nervals of dust Sampling, analysis, and evalution before all of the unanswered health problems could be resolved. 'ISCUSSION: -of ^ . ^ e s t i g a t i o n s were actually initiated for the general purposes a c t S htoSfiCai?*w-JdenttflCatlon " PurPose^y for'clarification ofthe actual hazard to health (if any) connected with the fabrication of three different matrials ^ d identification of acceptable measures for use in reducing all exposures to within safe acceptable limits. However, each investigate ^ occurred for clearly identifiable reasons as explained tolow: The investigation of 24 Jan 63 was conducted because: 1. pie Johns tonville Company submitted a report, compiled by their Research Department, ^which contained data that conflicted with that submitted by this department in Report 62-IH-l-G-l. 2. This department desired to clarify the reasons for the discrepancy between the tv reports and to identify positively, the actual conditions as they exist in the working, environment. ' The investigation of 25 and 26 Feb 63 was conducted because: 1. In the preceding investigation, the two insulation materials in question, i.e., "Thermobestos" and "Kaylo" were: evaluated inadvertently during the same afternoon, a procedure which was not in keeping with an attempt to stimulate the conditions of the original report. In the original report, each material was evaluated on separate occasions so as to preclude the possibility that any one sample might contain dust produced by both operations. A 0 8 6 `V 3. , * *18 Kaylo" insulation ^ material hhaadd ttoo bhe re ev alu a ted . . investigation of 6 ta , lss3 w s a new insulation ^ ^ P p S S ^ ^ ^ ^ ^ ^ r e o n n t l y tad installed lt^v^Te nslot0ta s to s*v dt usht oi o Tn c S^ t ii o S^ 1 S . ' Ws Si^ a M e S^int^S the saTM * * ^ ^ d S ^ 0" * * * h i--, each tat " Pling P ^ c e d u r e ^ u u i S 6^ accordance with th.'fol5 01;1? "ethods of faSiSio m v **"Wrt, ^ i d e ^ th* as follows: since this is standard p r a c t i c e d at^efch h^ d sfw of any insulation material. f Uowed m the fabrication Second: The environmental oona:-*-- - i.e.f 62-IH-l-G-i and 6 2 - 1 ^ 2 ^ 1 pnecedin sports, ( outside ,doors to the buildi^ 'v ^ c S s ^ ' ^ ^ tthhat ThiVdi 5*ch dust sample was collected in th . # - n e as ha c k e d in t l c a ^ p TM ^ * " * * v ^ t a t^ dow ndrifv e S ilS i ^ r a tS m '' =SuLtion blocks ^ ^ ^ ig in a l evaluate ^ " TM W been installed ^ S S ^ S ^ S . f ir s t: The complete fabrication of "tv- v vTMentilation in "op*e*r>a'tion P t a T ,r^i Sth0361,"1, ^availaoble blocks downdraft ventilation i ^ t ^ 'wlth ^ the original Second: The complete fehni a.* was evaluated w h i l e ^ t i l L ^ / ^ 7"1^ 5" ijlsulation blocks ventilation. . i n g all available exhaust A4-86S included as a without supplementary exieust ven tilatio n ) the TLV o f 20 mppef o f a ir a n d lto r S S T le ' th at aught be added should be L re than EVALUATIONS: not disnloeea1* 1! lnVeStlSatlon' ^P^ionned fnly '^ L 'xP sure ' d in g o* S o 'S K S L ^ tU a ti=" A. Atmospheric dust exposures: 1. ^ S S ^ y ^ e 1 f1S f ? S e % d ^ sI^ S?'t " M * when detemun^in a. Sde2scriibbe2daoonnpPfacgfefld9o,ni,wleeredifseflrecetnetdfeodriteivoanlusatoifone.xposure, as be ^ S S t V "^ 1TM W t h e use of th. apparatus (described on Page s T l e r v ^ as t S S use. C" ttetc^hgniqruSes^ assr Sd ef ^ rr ft tS3 Lo ^^ l S" ef ? ' i lHea'ih * san,ll ra"sTMe<s*taWblished 2. s ^ r ^ b iS t o ^ f s 1?s.oL i i S * i ? S o f ^ n ^ i 01, * * * y yi" ^ i T ^ o n X ^ y o1 ntSS US s S 't ^ sawing techrquesas well as " sulation materials since the to the inch operating a t ^ O O l i i S T w ' ' ' ' *ladeS with three teeth both occasionsand^therefore S H i . o f ' X ' T - ', " ^ identical on expected to deviate to any grit degree froa t h f ^ S ' i e S S d v u . 3. ^?^oV^stt^ rsepioritedr assbelnfe ifdenltica s r smastesrisalis ussejdf osn rbo^th c-cc'asi*o-ns*.were ^ 'Carey-Temp" was not established^ ^ `e a ^ U e r ^ t e ^ r w a d ^ 3^ 100 linperative that it be determined and reported* t h i f t W a?.deemed accomplished as described on Page 5. ^ thiS tljne* Thls ^ B. Local exhaust ventilation controls: . 1. S e n ^ f o ^ h ^ ^ ^ l t S " ? 1t,TOUgh the vant i" >* ifa d e lfo AnemotherTiir meta ^ ,2> " * measurad throuSh the use of a 2. Four variable conditions of interest were evaluated: * * * S S c S s ^ s t ^ S ^ ' o 1? f a??p ^ ti0n> tha of dust-free watlr a i S ^ ^ " geI' ilask teodon ^ Mus * n < * * * * of atirospheric specific voluS ' A U 4- 8 6 1; conclusions. ` o rigin al downrfr^? diodes could be fa iw fl banndd ssaaw?,^ad^ fct oerxrehcatuesdt. v^iittiU{ia-.t?"*nh*rIifcaetexdi sstaif^e1l^v uf,- I f 1."* J tha 3` " ^ l o " In scla tlce w, the en tire *vu '100 ^oohs d efin ite! ' C b s w ) * the Fm c!>* S a^ Sad US as bTelow?L From ph #2 E TabAlee*ss oocnn,, FPpa*ggeess 88 S 99.. 2 MttfkO* . . * ' " u" a^ *i a afha bl eri,c"a t' ;eKdl wh. ^ Vsu* ' Lrn* nta*tO blocJcs f : dr r r j f^ y ^ -tH , c : : s T 10TM " ^ W t a . S i e ^ m i c n w s revealed as J ^ ^ C> * only one ,, Ventliion bein* used. "e f w i t % * * . SS ? S' p s ths W ? J t t a t i n the samples tap, SSST "dolly"^fop frTOVed fror! tiS li1^ i*** U sd up*" t i tes r8vedls: -Cnonssesqrueenattleyr,tSthne ^duS-* ^" Pt"11^ 1cvenrtheXn *^5" na*tul abrasion^ 2. 11 supplements, 8 this location preceding tJ!**** 0Verhead ventil.of , However S-it^Lni!ports^ does sn^ ^ 00 (added since tH. f ironj-GrPap^h #3e g T.M ' ' Tai>la on Page 9. 1. ^rey-Temp* dust 33 ^ o / f ^ s y s s . 5 S s .* witfm, safe i5 % W8 sub t hmsari exposuriis, 1>e A 0 4 8 6 :: b- ^ 2 i tad - -- * * d- ^ ^ nXJRES: ^th ^ Pling and analytical methods were as follows: SAMPLING: Srp1i ?n^fhiSirn311^ 3- -l cubiJTe^f 1- the 3=1,131 concentrations in sir wens double d S n ^ 1 S t - f S ^ t ^ aSkS cont3ini^ " -illiliters of 2` W , ' 5 u l f f i r lil,J 1* distribution data ere pump, P O ^ fUters connected to a snail battery-operated ANALYTICAL: \ 1. Each dust sample was evaluated through th# n - .. referred to as the light field McreSrpic S L o ,, g 2. First^the saTpl^wa^precared ` ^ 2 f s3PJTate sources, mounting nethod.+ Second the ar-hwl^8 -1^ accordance with a permanent accordance with the ^accomplished in micrometer and a standard micro depicting the use of a filar dry) and the 97X (oil i s J S S f ^ S w s T ''8 **" th3 *3X <hiS 3. RESULTS: " S c V S ^ s th. analysis performed by Mr Thomas*^ ^'c^.seco^d; through contracted Foundation/IncT^Saramk Chenist for the ^ u See Pages 8, 9, 10 and 11. Drinker and Hatch: "Industrial T W 9rv, Inc. , New York, 195*+. * Edition, pp. 152-153, McGraw-Hill Book Company, in Pautus, Hi J., Talvitie, N. A., Fraser D A Air Sampling", A.I.H.A. W 5 y Vol* ? n ^ ' ? * i * ^ " Use f Drinker and Hatch: "IncEstfl Dust" ?/+ r!*.- p* 269* ^Pt ember, 1957. Filters Ine., New York, 195*+. ^ * 2nd Edltlon* PP* 166-179, McGraw-Hill Book Company, 048 6 ? 7. J 2 i - W . M saws Relative to the exhaust ventilation system: is S l ?us ^000^. OT bth ^ Mws 1" d is RECOhfrOJDAIIONS; ' t S a i f S S : 18" X 36" * " =r " I ^ t e s t o s " N a t i o n a' S ^ t existing system, or P ^ - W * of air v^ U a t i b n techniques or repairs to the b. The manufacturers of the tve Mt.e to produce a product uhich w i u ^ o t roleSe'* *ble baud saw, dust concentrations i n ^ s s o ^ O ^ i T a S " " * REP:hl 23 October 1963 Submitted by: T T I V Peele r `" Industrial Hygienist 0 4 8 3 ' Evalut rm . . INOSTRIAL HYGIENE SURVEY 8. 1'Mt" " of Adaptor* Bert Conditio at tto Const^ction Insulation Stop Atmospheric Eust Concentration E&ta Collected When Using Only Partial Ventilation, i.e., Only Below the Blocks Cutting t Edging Insulation Blocks Cutting a Radius on Insulation Blocks 04870 Table #2 9. Atmospheric Dust Concentration Data VVeenntitlai ltiaoSn,^ i .e3.,WhBenothUsAnbgovMe 1 BAevloawilatbhlee Blo'cks Cutting S Edging Insulation Blocks 6 Mar 63 26 Feb 63 26 Feb 63 Type of Material Thermobestos Thermobestos Carey-Temp Carey-Temp Description of Location #3a, i.e., South Side of the #2 Band Saw fifu*+ia*, V6*' Sl"ith Sid"e ofn thfe 11ii Bannd Snaw #Sa, i.e., North Side of the 11 Band Saw Concentration in mppcf 22.42 51.70 85.40 100.90 Index for Graphs II, |2 |3 #1 12 * = South 1 Side rt #2 Band it It 13 = rt 11 12 it 14 s ft tt #1 tt ft lia = rt n #2 n ft 12a = tt rt 11 n rt 13a n H 12 it tf 14a n 11 n 1155aa == North Side 011 BBaanndd Saw -- -- - Edging -- '* _ - Cutting a Radius - "ww - Cutting Blocks - - Edging " _ Catt9ting a M Radius ~ _ 7 Cutting a Radius Vt It n -- rt vt _ 19 tt Both Above S Below n - n t, " " " it,, - Ventilation Both Above Below A0 48 7 I ^ . . Table 13 10. Percenta Crystalline !*ee Silica Present in "Thermobestos", "Kaylo" S "Carey-Tenm" as Quartz by the "Talvitie" Method ^ ^"Thermobestos" (As Contained in Report 62-IH-l-G-l) 1 2 3 Trial i 1 2 3- 0.5002 0.5000 0.5002 0.0390 0.0347 0.0396 0.0069 0.0068 0.0082 Average Percentage Crystalline Free S1O2 = 6.4 6.42 5.58 6.28 _ "Kaylo" (As Contained in Report 62-IH-l-G-l) in Grams W2 in Grams W3 in Grams % FY'ee 0.5000 0.5000 0.5000 0.0807 0.0730 0.0563 0.0433 0.0364 0.0190 7.48 7.32 7.46 Average Percentage Crystalline Free S1O2 = 7.4 n "Carey-Temp" (As Reported by Mr. Theras M. Durkan) 4 October 1963 Components Soluble in Hcl Other Components Soluble in Phosphoric Acid Percentage Crystalline Free Sx02 as Quartz 1808.. 88%% 99.6% 00.4% 11. . Table Ventilation Kates on Two Band Saws. / (''/. O *7 -1 h uTu / I J GRAPH NO. 1 DUST EXPOSURES W HILE FABRICATING KA YLO & THERMOBESTOS INSULATION B IO C K S W ITH ONLY DOW NDRAFT VENTILATIO 4 f\ Ban4 Stv S-frO? t loo DUST EXPOSURES W HILE FABRICATING.; t THERMOBESTOS & CAREY-TEMP INSUIAHO BLOCKS WITH BOTH DOWNDRAFT AND OVERHEAD VENTILATION T.L.V.