Document 6bVD1ggRjqzjmorEjqbBEkrKg

V TO: Bob Whitlow Interoffice Communication FROM: DATE: SUBJ: T. G. Grumbles September 13, 1990 BENZENE, TOLUENE AND XYLENE EXPOSURE CONTROL PROGRAMS VISTA Vista has benzene present at the Lake Charles Chemical and Lake Charles LAB plant and the Baltimore plant. The Baltimore plant also has toluene and xylene present. Based on the presence of these chemicals, exposure control programs and procedures are in-place to control workplace exposures. Below is a summary of those programs. It should be noted that benzene use is strictly regulated by the Environmental Protection Agency and the Occupational Safety and Health Administration. This regulatory control is enforced at a State and Federal level. Employee Training Vista has developed a training program for Benzene that covers general safety and health information on benzene and plant or location specific safe handling and emergency procedures. Employees are trained on an annual basis. The basic script for this program is attached. The hazards of toluene and xylene are covered in the plants general hazard communication program. Exposure Monitoring Employee exposures to benzene are routinely monitored by personal exposure measurements and fixed-point area continuous monitoring. The frequency of personal monitoring varies at each location but exceeds OSHA monitoring requirements. A summary of benzene exposures at the LCLAB and Baltimore plants is attached. Benzene is a by-product of the ethylene production process at the LCCP. Due to a major turnaround and construction project on this unit, it was not possible to obtain routing exposure summary information. However, the results from monitoring done during the initial stages of the turnaround are described in the attachment. Toluene and xylene exposure data for Baltimore is also included in the attachment. The fixed-point area monitoring systems are used to measure ambient concentrations of benzene throughout the plants. Monitoring results are displayed in the control room and audible alarms set at specific concentration levels to provide early leak detection and assure the appropriate level of personal protective equipment is worn when responding to leaks. 000013&95 Exposure Controls Exposure controls consist of a combination of engineering controls, personal protective equipment (respirator) use and administrative procedures. Exposure controls include equipment specifications to fugitive emissions, closed process sewers, closed-loop systems and localized exhaust ventilation where feasible. minimize sampling All plants have specific, detailed respiratory protection programs specifying types of respirators to be used, conditions of use, training, and fit-testing. For the most part, Vista plants do not use air-purifying, negative pressure respirators for routine exposure controls. Air-supplied, positive pressure respirators, which provide a higher protection factor, are used in most routine jobs requiring respiratory protection. Administrative procedures include work practices and policies dictating equipment preparation prior to opening, tank gauging, product loading and storage, and procedures to be used for other specific activities identified as having the potential for benzene exposure. In addition to the above items all employees routinely exposed to benzene are provided the opportunity to take a multi-phasic physical exam designed to give early detection of benzene exposure effects. In the event of an emergency exposure, employees are required to participate in a urinalysis test that will help indicate if significant exposure has occurred. In summary, Vista has formal programs in-place to control and monitor exposures to benzene, toluene and xylene in our manufacturing locations with the potential for exposures to these chemicals. Exposure monitoring results indicate current workplace exposure levels are well below applicable permissible exposure limits. T. G. Grumbles dlj cc: R. D. Gamblin, J. A. DeBernardi VVV 000013696 BENZENE EXPOSURE DATA SUMMARIES PERSONAL. FULL-SHIFT MEASUREMENTS (ppm) Concentration BALTIMORE 1990 No. of Measurements LCLAB 1990 No. of Measurements LCLAB 1989 No. of Measurements 0-0.59 83 82 117 0.6-0,99 400 1.0-5,0 301 LCCP benzene exposure measurements during recent ethylene unit turnaround: of 200 measurements made only one exceeded 1.0 ppm at 1.07 ppm. All Baltimore toluene and xylene exposure measurements in 1989 and 1990 to date are less than 0.3 ppm. VVV 000013697 UI DEQ (Third Draft ------ 7/i7/c! 8) Super Name and Title '.Edit, add plant e x t e r i o r s.) BENZENE: WHAT IT IS HOW IT AFFECTS YOU WHERE IT IS FOUND HOW TO PROTECT YOURSSELF OSHA REGULATIONS General plant footage AUDIO I INTRODUCTION A. Oe Bern adi Page 1 < F ade to Black) (Music, not so loud) Today we "'re going to discuss benzene. We want you to know what it is... How it can affect your health... Where it is found in our pi ant. . . How you can protect yourself. . . And important information regarding the Occupational Safety and Health Administration, or OSHA, re gu1 ation s for benzene . If handled carelessly or unwisely, benzene can be very hazardous. We have developed engineering controls and safe work practices to reduce your exposure to benzene. As additional information becomes available, further efforts will VVV 000013698 VIDEO AUDIO Pace 2 be made to deve ] op con tro i = and procedures to insure that your exposure to benzene is below the permissible e xpo s u r e limits. P*op 1e wonking in plant But achieving this requires your cooperation, and the purpose ot this program is to give you in-formation that will allow you to be a -full partner in protecting /our safety and health, and t h a t o-f you r -fell ow wor kers. MSDS and other documents BENZENE: UNDERSTANDING AND HANDLING ITS HAZARDS Important written i n-forma t i on on benzene, its hazards, regulations involving its use or manufacture, and sate practices tor handling it, is available to you through your plant a (- j existing hazard communication programs. What tollows is an overview ot the hazards posed by benzene, and the steps we will take together to handle them sate1y. II. WHAT IS BENZENE? List Let's- begin by explaining what benzene is, and how exposure to it can attect you . Benzene is a clear, colorless liquid with a pleasant, sweet odor. VVV 000013699 UI DEO ''Person smells, notifies List List List AUDIO Page If you believe you smell benzene you should notify your- supervisor immediately, and take appropriate action to find the source. Levels at which you can detect benzene's odor may be above those considered safe. This means it could harm you before you c an sme11 it. The chemical formula for benzene is C6H6. Some synonyms for benzene are Benzol, coal naptha, and phenyl hydride. Benzene is flammable, and it's very volatile. It has a f1 ash point of 12 degrees F.; an initial boiling point of 176 degrees F.; and a high evaporation rate. This means that significant vapor concentrations can build up even at a great distance from the point of re 1 ease . Benzene will float on water, having a specific gravity of 0.879, and a solubility in water of 0.0 67., or on 1 y 600 parts per million. 310 OOO^ viMSJ 0 VI DEO AUDIU Kaoe 4 Benzene- vapor is 2,7 times heavier than air, and wi 1 1 accumulate in 1ow pi aces such as sewers and trenches. III. HOW BENZENE CAN AFFECT YOUR HEALTH List Benzene can affect your health in a number of ways ... i -f you i nha) e it. or if it comes in contact with your skin or eyes. Benzene is also harm-ful i f you happen to swallow it. Acute & Chronic Effects of Exposure Benzene can have acute or chronic effects on your health. Acute Effects (List) Acute effects are those which occur rapidly: at the time of or soon after the exposure. Acute effects typically occur as a result of high exposures or exposure to the liquid. Chronic Effects (List) Chronic effects are those that occur over a long period of time, or after a long period of exposure to lower levels. SHORT-TERM (ACUTE) OVEREXPOSURE: Acute hazards of benzene include skin and eye irritation, and narcotic-1 ike effects on the central nervous system. yyV 000013701 UI PEG (List) LONG-TERM (CHRONIC) EXPOSURE: (List) AUDIO Page I-f you are overexposed to nigh concentrations of benzene, wei1 above the levels where its odor is first recognizable, you may feel breathless, irritable, euphoric, or giddy. You may experience irritation in eyes, nose and respiratory tract. You may develop a headache, feel dizzy, nauseated, or intoxicated. Severe exposures may lead to convulsions and loss of constiousness. Exposures above 2,000 parts per mill ion are considered to be immediately dangerous, to life and health. Chronic hazards include disorders of the blood and blood-forming organs. Repeated or prolonged exposure to benzene, even at relative)y 1ow concentrations may result in blood disorders, ranging from anemia to 1euKemiaYX an irreversible, often fatal b1ood cancer . Some b1ood disorders associated with benzene exposure may occur without syrnptoms. WV 000013702 ''I DEO (List) (List) LIMITS FOR EXPOSURE (List) Shot of the standard AUDI Q Page Benzene can toe absorbed through the sk in, resulting in toxic e f f e c t s . Acute contact with the skin can produce redness or irritation. Prolonged contact with the skin can produce a dry, sea 1 y type o-f dermat i t i s . Because o-f the hazards of benzene, we have established specific limits for your permissible exposure. In 1979, Conoco Chemicals established an internal exposure limit of 1 part per million on an 8-hour time weighted average basis, or TWA. Uista continued that internal exposure limitation. In September 1987, OSHA revised their occupational exposure limit from IQ parts per million to 1 part per million for an 8-hour TWA, and 5 parts per million for a 15 minute TWA. Th i s revision became effective in 1988. Copies of the standard and the appendices are avail-able to you upon request. VVV 000013703 MI DEG AIRBORNE EXPOSURE <List> EYE/SKIN CONTACT IU. WHERE BENZENE IS FOUND IN THE PLANT Training session AUDI 0 Page 7 For- airborne exposure, the maximum permissible exposure 1imit is 1 part of benzene uapor per mill ion parts of air, as .a t irne-we i qhted average, for an 8-hour workday. The maximum short-term exposure 1imit is 5 ppm, averaged over any 15 minute period. Eye and skin contact wi th benzene must be p revanted. High exposures to benzene may be encountered in any area where benzene is processed or stored. For example, high exposure can occur when you transfer benzene from one container to another. Such operations shou'l d be we 1 1 venti lated and good work practices must be followed to avoid spills. You wi11 be advised of al1 plant areas and operations where exposure to benzene could occur. If you ever have a question a bout a certain area, or suspect a 1eak or spill, see your supervisor at once. 00013704 V-11 DEO AUDI Q Page Regulated area in plant DANGER BENZENE CANCER HAZARD FLAMMABLE - NO SMOKING AUTHORIZED PERSONNEL ONLY RESPIRATOR REQUIRED Show variety of containers DANGER CONTAINS BENZENE Certain parts of the plant may be designated as Regulated Areas. These are areas where airborne concentrations of benzene exceed or me.y e x c e e d the permissible exposure 1imits. These areas will be restricted to authorized persons, and respirators will be required. The entrances to any regulated area wi 1 bear the foilowing warning: These regulated areas may be permanent, or they may be temporarily establisned du ring specified oper ations. In addition to existing hazard communication signs, containers and process, vessels with a 0 . 1X or greater content of benzene will bear this label 013705 WI DEO CAN C E R HA Z A R 0 AUDIO Race ? U. HOW YOU CAN PROTECT YOURSELF Wista will be continuing various engineering controls and work practices to keep your exposure to benzene at or below the permissible exposure limits. Workers in plant In some situations, these steps alone -are not enough, and we must use additional protect i ye equ i pmen t . RESPIRATORS < List) Respirators are required tor those operations in which engineering or work practice controls are not feasible to reduce exposure to the permissible legal , or where benzene is present in the workplace for less than 30 days per year. Fit testing in progress You wi11 be supplied with appropriate respiratory protection equipment at no cost tc> you. Wist a wi 1 1 perform! tests to assure your respirator face piece fits properly, when you are first assigned to work in an area, where benzene is made or used, and p e riodic a 11y thereafter. VVV 000013706 MI DEO Training in p r o g r e = s Worker using air)ine reap. PROTECTIME CLOTHING: EYE AND FACE PROTECTION: AUD I 0 Page 10 Mista wi11 prouide you with thorough training in the use and limitations of the respiratory equipment you are required to use. When you are required to use respiratory equipment, you must ensure the respirator is operating p*roperly before beginning any work on equipment containing benzene, or entering any area. known to be contaminated with benzene. IF you have any trouble with your respirator, leave the area and contact your supervisor for assistance immediat e1y. You must use protective clothing, such as boots, gloves, sleeves, aprons, and rain gear- or si icker- suits, over any parts of your body that could be exposed to liquid benzene. If it is possible that benzene may get into your eyes, you must wear a face-shield, goggles, or both, depending on you r particular situation. You must wear a face shield if your face could be splashed with liquid benzene. Vvv 00001370? WI DEO audio Page n EMERGENCY AND FIRST AID PROCEDURES It is important that you Know and follow spec i f i c emergency and first aid procedures, should any exposure to benzene 1iquid or vapors occur. EYE AND FACE EXPOSURE: E y e -w ash scene Notifying supervisor If benzene is splashed in your eyes. wash it out immediate!y with 1arge amounts of water. If irritation pers i sts- or v i s i on appears- to be affected seek medical attention as soon as pass- i bl e . If an injury occurs, follow established procedures for notifying your supervisor or the safety director regarding that i njury, SKIN EXPOSURE: UJash i no arms If benzene is spilled on your clothing o r s kin, r emov e the contaminated clothing ana 'wash the exposed skin with large amounts of water and soap immediately. Wash contaminated clothing, including shoes and socks, before you wear them again. AIRBORNE EXPOSURE: If you or any other person breathes in large amounts of benzene, get the exposed person to fresh air at once. VVV 000013708 VI DEO < L i st > RESCUE PROCEDURE: SWALLOWI NS: AUDI 0 Page 1A App 1 > artificial r e sp i r a t i on i f breathing has stopped. Call tor emergency medical assistance or a doc t imm e dia t e1v. If it becomes necessary to enter a vessel or confined space for rescue purposes, follow the estahlished rules and procedures for uessel entry. If benzene has been swallowed, do not induce ting. Call for emergency me dic a 1 assistance immedia te1y. WI. MEDICAL SURVEILLANCE PROGRAM (Dr. Drumwright On Camera) Vista's medical survei 1 1 ance program * designed to detect the early signs of toxic effects, particularly in abnormal i ties of red hiood cel Is, whi t blood cells, and platelets. A?1 new emp1ovees will be giyen an initial exam and lab test with a complete blood count. For those employees, who may be required to wearrespirator, pulmonary function tests will also be performed. Your medical history, specifically regarding bone VVV 000013709 AUDI 0 Paae 13 mar r ow p r ob I ems an d b i c>od~r el a t e d disorders, will become part of your records. 1f you are e xposed t o benzene a b ove permissible exposure limits, or if you have ever been exposed to 10 parts per mill ion TWA or above, whi 1e emp)oyed by Mist a, you will be provided with an annual medical examination and 1 abor a t o r y tests. These tests, w ill be provided at no cost to you. While these tests are not mandatory, you are encouraged to participate, as it \ =. an integral part of our benzene safety and health program. If you dec! ine, you will be asked to sign a waiver statement sig nif yin g that y o u were offered the opportunity and that you understand the risks of not participating. If you are accidenta 1 1y exposed to benzene, or may have been, Wista will make special laboratory tests available to you. In the event of an emergency exposure, you wi11 also be asked to provide a urine sample, on which a urinary phenol VVV 000013710 1 ' IDEQ Shots of records and notices AUDIO Page 1 4 test i'j ill be pert or-rne d . This i s a q u i c k wax to determine if your exposure to benzene may have been =uti i c i ent to cause adverse effects. The purpose oi this test i s = o 1 e 1 v t o detect possible health effects resulting from the exposure to benzene, and no other analysis will be performed. All medical records and exposure noni torinq records are aval 1 able to you by following currently established plant procedures. Notices are posted in the plants regarding procedures for obtaining these recor ds. ( END OF DR. DRUMUiRI 6HT *' S SECTION) UII. EXPOSURE MONITORING PROGRAM (NARRATOR CONTINUES) Wis t a mak e s periodic me asu rerne nt s t o determine vour exposure to benzene. We do this by t ak' i ng br eath i ng zone air samples from employees, in areas where benzene may be present, and with continuous fixe d-poin t moni toning. Emp1oye e obse rving moni toning Y ou or you r desiqn a t e d re p r e se n t a tiv e may observe the monitoring procedure. vvv OOQOX^7*1 VIDEO Protect(Me equipment i n use AUDIO Pace 15 When mon i toning takes place in an area. where resp i rat or*, or personal protec t i ue equipment must be worn, you or vour represen tat i Me wi 1 1 be prc-M i ded w.h th , and must use that equipment, No t i f i c a t i o n p o s t & d Wit hin 15 won king days of the receipt of the results of any monitoring performed, Vista will notify each employee of these r e so Its in wr i t i n g , either i n d i v i ou a 1 1 y or dy posting the results in an appropriate and accessih)e )ocation. Close-up corrett ? ye a t s on notice Whenever- permissible exposure level*, are exceeded, the written notification will also contain the corrective action being taken to reduce your exposure, or will refer you to a document which states the correct i ve actions to be t-aken . VI I I . PRECAUTIONS FOR 'hAFE USE, HANDLING AND STORAGE In addition to its health hazards, benzene also poses a severe danger of fire and exp1 osion, if not proper1y handled and stored. We must all follow certain precautions for its safe use, handling and storage. vvv 0000137*2 VIDEO lontainers, close-up labels List) Li s t (List) Workers taking precautions No Smoking Sign AUDIO Haqe 16 Benzene liquid is high) y f1ammable. am all con ta i n e r -s con tain ing benzene should be t igh t 1 y c1ose d , and stored t n a coo1 , we 1 1 ') e n t i 1 a t e d ar e a . Benzene v a purs me. y -form e x p 1 o s i u e (Tt i x t u r e s i n air-. The ioiwe r e x o 1 os i v e limit is 1 . 3/1 o r 13,000 parts per mill ion . Unce agai n t h e 11 ash poi n t of benzen e i 12 degrees F. In o t h e r words, at th a t temperature, benzene is releasing hiyhl f1ammab1e vap ors. Exposure to heat or oxidizing materials increases benzenes instability. Whenever -fire or explosion hazards are possible, all sources of ignition must be eliminated. Use pract i ces wh I ch wi 1 1 avoi d spark i ng when opening or closing benzene containers, and be sure the containers are effectively grounded and bonded prior to opening or pouring. Smoking is prohibited in any area where benzene is used or stored. VVV 000013713 ' )I DEO AUDIO P-3- Q* 17 Pire tx t i n gu i sher= Fire ex tinguishers are re adi 1y av a i i ab 1 e . Know where they ape 1 ocated and how to operate them. *; Li st) Appropriate -first-aid extinguishers for benzene -fires are carbon dioxide, dry chemical or halogen. Do not use a sol id stream of water -for fire fighting, since this win scatter and spread the fire. A fine water sp ray can be use d to keep fire-exposed containers coo 1 . E xisting graphic fr om oId sh ow? Benzene v ap or a are heavier than air, and they can travel great distances along the ground and be ignited by open flames or sparks at some remote location. Worker reports- odor of benzene That-'s one reason it's important to report any suspected leak or spill at once, and to be on guard if a spi11 occurs in another- part of the plant. Super*-,' i sor takes measurements 'Show '/ar i e ty of devices used) IX. STEFS IN CASE OF RELEASE OR SPILL When in doubt, assume the hazard is real until measurements prove otherwise. WV 000013 714 FI ant procedures have been established in the event a spill or release of benzene occurs. oj DEO i sta LoQo . Copyright AUDIO r' e.ge i y continued ss.-fety o-f your te 1 1 ow workers and >' o u r =. $ I t . VW 000013715 C*! DEO XI. SUMMARY AND CONCLUSION AUDIO Page- 18 If possib1e. small spills should be flushed to the plant sewer, to allow for treatment in the plant. Benzene is a regulated hazardous waste for disposal purposes. In this program, we have discussed what benzene is, where it is found in your plant, the hazards that it poses, and how we can handle them safely. OSHA has now put into effect benzene exposure rules, establishing a limit of 1 part per million for an 8-hour time-weighted average, and 5 parts per mi 1 1 ion averaged over any 15 minute period. The 1 part per mill ion exposure 1 imi t has been in effect in our plants since 197? . Copies of the benzene standard are available to you. Just ask your supervisor or plant safety director for de t ai Is. By understanding and following these procedures, you wi11 help insure the VVV 000013716