Document 71yBKGxMVBYMzZDa0GRVxGGeV

ilFfioodrich INTER-ORGANIZATION CORRESPONDENCE IO M. E. Guyer FROM 0. G. Friesz SUBJECT FIELD POINT OR DEPT. & BLDG NO. Henry, IL FIELD POINT OR DEPT 6 BLDG NO. Henry, IL 1985 Industrial Hygiene Suirenarv - Henrv Plant DATE YOUR IfTTER DATE THIS Hilt# _______________________ 02/27/86__________ Henry Plant personnel were monitored for exposure to noise, nuisance dust (total and respirable), toxic heavy metals, benzene, and acetonitrile during 1985. The following exposure summaries reflect the results of this monitoring. I. NOISE (BPG Permissible Exposure Limit = 50% dose) (OSHA Permissible Exposure Limit = 100% dose) DuPont Mark I noise dosimeters were used to monitor employees for noise exposure. The dosimeter is worn by the employee to measure his total exposure to noise over the work shift. The noise dosimeter integrates all continuous, intermittent and impulsive sound levels over time to provide a reading of the cumulative noise exposure in percent dose. The BFGoodrich noise standard requires that each employee working in areas exceeding 85 decibels be monitored every other year. This monitoring was done during ,1984. During 1985, noise exposures were spot-checked by monitoring representative individuals from job classifications. Job Classification Building No. People Monitored Average Personnel Exposure (%) Compound Operator Recovery Operator Wastewater Treatment Operator Pearl Charge Operator BBTS Operator Lo Sope Charge Operator 3114 Operator 0BTS Operator Operator Helper Utilities S & E Operator 741 731 721 731 712 731 722 712 712 719 712 (Poly) (Sludge (Poly) (PC) (Poly) (PC) (PC) (Boiler (PC) dewatering) Hou s e) 3 1 2 1 2 2 2 1 3 1 133.52* 71.04 48.40 \ 47.64 47.25 42.06 41.00 37.30 32.00 28.25 13.50 Compound Operators working in the mill and/or henschel areas had the highest noise exposure average. This was the only job classification that exceeded the OSHA permissible exposure limit of 100% dose. BF-G-495&- NGC 01334 Page 2 Sound attenuation curtains were installed around the Compounding weight scale in October. Various other sound attenuating materials and devices are being installed at the henschel. Overall, noise exposure in the henschel and weighman's area has been reduced by approximately 6 decibels (equivalent to cutting the sound pressure in half). Seventy percent of the employees monitored for noise exposure during 1965 were less than 50% dose. All of the employees exceeding 50% dose wore hearing protection. II. DUST (Total Dust Exposure Limit = 10 mg/H3) (Respirable Dust Exposure Limit = 5 rog/H3) (Toxic Dust Exposure Limit: Antimony = 0.05 mg/M3 Cadmium = 0.05 rag/M3 Chromium =0.05 mg/H^ Nickel = 1.0 mg/m3 A. Unspecified, non-toxic dust in the respirable and non-respirable size range is termed total dust. Polymer Chemical employees who bag product were spot-checked for dust exposure in 1985 since previous exposures have been low. The average total dust exposure was 2.00 mg/M3 and there were no individual exposures exceeding the specified Limit. < B. Dust consisting primarily of PVC was monitored in the total size range and in the respirable range. Employee monitoring for PVC total dust in the Dryer Building and Compounding averaged 1.2 mg/M3. A spot-check of respirable range dust exposure in the Dryer Building averaged 0.10 mg/M3. There were no exposures exceeding the specified limits. C. The henschel operator and weighman in compounding were monitored for exposure to pigment dusts containing heavy metals. The sampling filters were then sent to the Brecksville Environmental Laboratory for analysis by atomic absorption spectrophotometry. There were no samples that exceeded the heavy metal exposure limits. Monitoring done during 1984 also indicated that there are no exposure problems. AVERAGE PERSONNEL EXPOSURE TO HEAVY METALS IN COMPOUNDING Antimony = 0-005 mg/M3 Cadmium = 0.002 mg/M3 Chromium = 0.004 mg/M3 Nickel = 0.01 mg/M3 Several weld shop employees were monitored for exposure to fumes containing lead, chromium and nickel in order to verify the adequacy of welding booth ventilation. Ail sample results were below the permissible exposure limits for these heavy metals. NGC OS 335 Page 3 III. BENZENE (BFG Permissible Exposure Limit = I ppm) (OSKA Permissible Exposure Limit = 10 ppm) (OSHA Proposed Permissible Exposure Limit 1 ppm) Due to continuing low benzene exposure levels, monitoring during 1985 was reduced to monthly for a representative operator on the X-70 and Geltrol processes, and annually for a representative of each other job classification where there may be benzene exposure. Thirty-four employees in the Polymer Chemicals (PC) Building, PC Laboratory, PC Maintenance, and the Sludge Dewatering Building were monitored for benzene exposures during 1985. Only two exposures were greater than 1 ppm, and one of these exceeded 10 ppm. The remaining samples (94%) were less than 0.5 ppm. The high benzene exposure (16.5 ppm) was to a Polymer Chemicals Laboratory operator who had set up several process samples under the hood. Although both samples contained benzene, other laboratory operators monitored under the same conditions had never shown excessive exposure. The highest laboratory exposure to benzene during 1984 was 1.26 ppm; the average annual exposure was 0.33 ppm. Further investigation disclosed that the operator had set up other samples during the day that involved heating methanol. As a test, a 3M organic Vapor Badge (which is the same device used for benzene monitoring) was exposed to hot methanol vapors for fifteen minutes. With the cooperation of the Brecksville Laboratory, the sample was analyzed for benzene. The analysis result was 7.1 ppm. It appears that methanol vapors can interfere with the benzene analysis method. If the lab is expecting to see benzene in a sample, then the methanol interference peak may not be discerned. The second benzene exposure greater than one ppm (2.80 ppm) occurred when a Polymer Chemical Maintenance operator was repairing leaks at the wet benzene meter and the bottom valve of the X-70 reactor. A fresh-air mask was worn at the time of the repair job. 1985 BENZENE EXPOSURE (PPM) BY JOB CLASSIFICATION Job Classification No. People Monitored Average Personnel Exposure (ppm) PC Maintenance PC Bagger Wastewater Treatment Operator PC Laboratory Operator MBTS Operator BBTS Operator X-70 Operator Geltrol Operator Stalite Operator OBTS Operator 3 1 4 2 1 1 9 7 2 3 1.08 0.30 0.30 0.30(*) 0.20 0.20 0.20 0.19 0.18 0.13 (*) The high benzene exposure result which was due to the methanol interference was coded as an invalid sample and not included in the average. Page 4 YEAWY BENZENE EXPOSURE AVERAGES Year 1982 1983 1984 1985 Average PPM 0.29 0.34 0.38 0.29 IV. ACETONITRILE (BFG and OSHA Permissible Exposure Limit a 40 ppm) Personnel monitoring for acetonitrile has also been reduced due to low exposure levels. Operators in the 3114 Building (722) are spot-checked for Acetonitrile exposure. Spot-check monitoring will also be done during any special operations in the 3114 Building. For 1985, the Acetonitrile exposure average was 0.64 ppm. V. VINYL CHLORIDE (BFGoodrich and OSHA Permissible Exposure Limit 1 ppm) All operators in the Poly and Dryer Buildings as well as the PVC Tank Farm are monitored for vinyl chloride exposure at least once per year. The schedule of monitoring then follows the OSHA VC1 standard which requires monthly monitoring for any exposure greater than 1 ppm or quarterly monitoring for any exposure greater than 0.5 ppm until two consecutive monitorings are less than 0.5 ppm. The employee need not be monitored again during the year if his annual monitoring result or the two consecutive monitorings are below 0.5 ppm. The VC1 monitoring samples are then sent to the Brecksville Environmental Laboratory for analysis. The 1985 VC1 personnel monitoring results are summarized below: Year 1983 1984 1985 VINYL CHLORIDE MONITORING (POLY AND DRYER BUILDING) No. of People Monitored Average (PPM) % Greater Than 1 PPM 152 165 231 0.82 0.67 1.58 15 15 38 Year 1983 1984 1985 RESPIRATOR COMPLIANCE (POLY BLDG.) No. of Exposures Greater Than 1 PPM No. of Exposures Greater Than 1 W/0 Respirator 23 10 25 5 87 33 Respirator Compliance 5 7% 80% 62% 01337 Page 5 Job Class VINYL CHLORIDE EXPOSURE BY JOB CLASSIFICATION No. of People Monitored Average (PPM) Helper/KRC Poly Cleaner Lo Sope Charge Pearl Charge Recovery Production Foreman (Poly Bldg.) Vinyl Tank Farm Operator Dryer Operator Production Foreman (Dryer Bldg.) Helper/Dryer Bldg. Bagger S & E Operator Catalyst Make-up Silo Operator 21 46 51 24 20 2 23 8 15 1 4 5 3.09 1.66 1.63 1.21 1.12 1.03 0.99 0.59 0.57 0.56 0.47 0.43 Obviously, the VCl personnel exposure Levels have Increased during 1985. This may be due in part to the Reizner gas badges which have been used for VC1 exposure monitoring since 5/15/85. Although the Reizner badge and the head-space/GC analysis method are reported to have greater accuracy for VCl than the previously used PMCC tube/GC method, il*ra surprised to see such a large increase in Henry Plant exposures. Other plants using the Reizner gas badge have also seen an increase in VCl exposure levels (20-40% greater than the 1984 average) and some high results that were unexplainable. There seem to be no other chemicals in the Poly building that will interfere with VCl analysis of the Reizner badge. I've placed duplicate badges on several employees and requested mass spectrophotometer analysis on the second badge. Each test showed a peak that was clearly vinyl chloride with no interfering peaks. The Brecksville Laboratory is presently investigating possible contamination of the charcoal vials or other problems that could cause erroneously high test results. In the meantime, any sample for which the VCl result is high and unexplainable will be voided out and the employee remonitored. VI. SPECIAL PROJECTS A. Area monitoring in the sludge dewatering building during the winter of 1964/1985 revealed that benzene and vinyl chloride were concentrating in the area when all doors were closed to an average of 5.5 ppm and 3.0 ppm, respectively. Wall exhaust fans were installed in the building during the summer. Area exposures now average 0.10 ppm benzene and 0.29 ppm vinyl chloride. B. As an energy saving measure, ventilation rates on all floors of the PC building (712) and 3114 building (722) were reduced from 12 air exchanges per hour to eight during February, 1985. There has no significant employee exposure impact as a result of this change. - 0)338 Page. 6 In conclusion, the vinyl chloride monitoring situation is the most serious industrial hygiene concern at this time. The last two sets of analysis results from the Brecksville laboratory have improved with more low exposures and fewer unexplainable exposures without respirator protection. Hopefully, the trend will continue. Other personnel monitoring results for 1985 continue to show a trend of decreasing chemical exposures. The Henry Plant should have no trouble meeting the 1 ppm benzene exposure limit if the proposed standard is finalized. wpghl9/0114Q Distribution: R. J. Grahek M. E. Guyer D. B. Giffin D. L. Rys W. B. Bispeck K. J. Willings J. V. Hordmeyer T. S. Bialke Diana G. Friesz *Cr 0J339 itpGoodrich INTER-ORGANIZATION CORRESPONDENCE 1 TO M.E. GUYER FIELD POINT OR DEPT. & BLDG NO HENRY PLANT FPOM FIELD POINT OR DEPT. & BLDG NO. DIANA FRIESZ HENRY PLANT SUBJECT INDUSTRIAL HYGIENE UPDATE FOR THE SECOND QUARTER OF 1985 DATE YOUR LETTER DATE THIS LETTER 7/31/85 5%bl sd tm vn jj The Henry Plant personnel monitoring results for the first quarter 1985 are sum marized as follows: BUILDING NUMBER OF PERSONNEL MONITORED AVERAGE PERSONNEL EXPOSURE I. NOISE (BFG Permissible Exposure Limit = 50%) Polymer Chemicals (712) Poly Building 3114 Building Boiler House 2 5 1 3 47.25% 50.1 % 64.0 % 28.25% II. DUST/TOTAL UNSPECIFIED (Permissible. Exposure Limit = 10 mg/M3) Polymer Chemicals 4 2.7 mg/M3 DUST/HEAVY METALS Several dust samples were taken of Weld Shop personnel while cutting and welding on stainless and carbon steel. These samples were analyzed for lead, chromium and nickel by atomic absorption spectroscopy at the Brecksville Laboratory. All sample results were well below the permissible exposure limits these heavy metals. for III. BENZENE (BFG Permissible Exposure Limit = 1 ppm, OSHA Exposure Limit = 10 ppm) Polymer Chemicals Utilities (Sludge Dewatering) PC Maintenance 9 2 1 0.2 ppm 0,2 ppm 0.2 ppm IV. VINYL CHLORIDE (Permissible Exposure Limit = 1 ppm) Poly Building <+5 0.96 ppm LG-4956- 11/60 l ITHO IN U S A \GC 01340 INDUSTRIAL HYGIENE UPDATE FOR THE SECOND QUARTER OF 1985 (Cont'd-) 2. BUILDING NUMBER OF PERSONNEL MONITORED AVERAGE PERSONNEL EXPOSURE IV. VINYL CHLORIDE Dryer Building Utilities (Sludge Dewatering) PVC Tank Farm 13 3 1 0.66 ppm 0.40 ppm 1.20 ppm There were 62 VC1 personnel exposure samples taken during the second quarter of 1985. Of these, 19 samples (31%) exceeded 1 ppm. Ten (53%) of the samples that were greater than one ppm occurred without the use of a respirator. These people were questioned concerning their exposure to VC1 during monitoring and, in most cases, they were in no alarm lights and did nothing beyond routine, non-vinyl tasks. Almost all of the samples in question were col lected on the new Reizner gas badges. The possibility of a VC1 interference during analysis of these badges is presently being investigated. The PVC Tank Farm Operator was monitored during the short-term task of hooking-up and uncoupling VC1 tank cars in order to verify that these jobs are still respirator required tasks. The results for car hook-ups (average exposure - 8.9 ppm) and car uncoupling (average exposure - 4.4 ppm) indicate that a respirator is a continuing requirement for either task. NEW PROJECTS 1. Exhaust fans have been installed in the Sludge Dewatering Building in order to eliminate the wintertime concentration of Benzene and VC1. 2. Noise attenuation curtains have been ordered and will be installed around the Compounding weigh scales in order to reduce noise levels in the Henschel and Weigh Booth areas. Diana Friesz DF:bkw cc:R.J.Grahek "a K.J.Millings W.B.Bispeck R.V.Tebbutt T.S.Bialke J.A.Bernardi .1. V . Nordmeye r D.E.Giffin W.W.Walk File NGC 01341 ![FGoodrich INTER-ORGANIZATION CORRESPONDENCE TO M.E. GUYER FROM DIANA FRIESZ FIELD POINT OR DOT. 4 BLDG NO HENRY PLANT FIELD POINT OR DEPT, a BLDG- NO. HENRY PLANT SUBJECT INDUSTRIAL HYGIENE UPDATE FOR THE FIRST QUARTER OF 1985 DATE YOUR LETTS? DATE THIS LETTER 5/9/85 Henry Plant personnel monitoring results for the first quarter of 1985 are sum marized as follows: BUILDING NUMBER OF PERSONNEL MONITORED I. NOISE (BFG Permissible Exposure Limit = 50%) AVERAGE PERSONNEL EXPOSURE Polymer Chemicals (712) 3 29.4% The BF Goodrich noise standard requires that each person in noise exposure areas exceeding 85 decibels be monitored every second year. These people were monitored during 1984. For 1985, we will spot-check noise exposures by monitoring representative indivi duals in each job classification. II* DUST/TOTAL (Permissible Exposure Limit = 10 tng/M^) Polymer Chemicals 1712) 1 0.59 mg/M^ DUST/TOTAL PVC (Permissible Exposure Limit 10 tng/M^) Dryer Building (732) 1 2.94 mg/M^ DUST/RESPIRABLE PVC (Permissible Exposure Limit = 5 rag/M^) Dryer Building (732) 1 0.10 mg/M3 III. BENZENE (BFG Permissible Exposure Limit = 1 ppm, 0SHA Exposure Limit " 10 ppm) Polymer Chemicals (712) 11 0.18 ppm BCG- 49S6 fc. 11/go LI r HO IN U S A :01342 INDUSTRIAL HYGIENE UPDATE FOR THE FIRST QUARTER OF 1985 (Cone' d.) 2. Laboratory (718) Utilities (719) Maintenance (712) 2 2 1 0.30 ppm 0.40 ppm (D 2.80 ppm (2) (1) These operators were monitored while working in the Sludge Dewatering Building at Wastewater Treatment. The doors of the building were open at the time allowing adequate ventilation. (2) Monitoring was done while the Maintenance Operators completed a work order on equipment in benzene service. IV. VINYL CHLORIDE (Permissible Exposure Limit 1 ppm) Poly Building (731) Dryer Building (732) Utilities (719) 46 2 2 1.16 ppm 0.25 ppm 0.59 ppm (1) These operators were monitored while working in the Sludge Dewatering Building at Wastewater Treatment. The doors of the building were open at the time of monitoring. Thirteen of the first quarter vinyl chloride exposures exceeded 1 ppm. Of these, four (31%) were without the use of respirators. Three of the four exposed employees were Pearl charge or Pearl relief operators. I suspect that opening X500 polys after each charge has increased the exposure of employees in the immediate area. The operator who actually performs the reactor com pliance test with the THA probe is required to wear a respirator. These operators have been reinstructed to open the poly manhead only wide enough to insert the THA hose rather than to open it completely. This modified work practice should eliminate overexposures to nearby employees without res pirators . NEW PROJECTS It has been determined that vinyl chloride and benzene will concentrate to un acceptable levels in the Sludge Dewatering Building during wintertime operation when the doors are closed. A project is underway to design a ventilation system for this building which will be installed before next winter. DF:bkw cc: R.J.Grahek K.J.Millings W.B.Bispeck File R.V.Tebbutt T.S.Bialke 0-nV N'GC 01343 1/ IFGoodrich H&j _7 __ 5.70 qo Up Up 77 fO 7 7 _c2.j_2l 1 IX (p 50 _. 7 9 O 7 1 Sr 3 J 7 '/ >n 1 C7W 75 7 9 7 '< '7 If, 81 7 : 85 ___ 73 / ' 7/ r 3 `6 S .1i ';7 ' 0 m1 < Oy ' r l: 7 ! J -' ! - ^\ ci -.i I ; 4 - 9 1 x>& to (X Xi 3 Xo i*r o 7 7 ! Jp /;... 7; ./ ' ;7 9 0 ; *1 >/ lift ? D>- ? p7 2?9 i C\3 /o 7 )9s 5: 2_ 7 7'2- 9n 79 79 -7 ? 3 r `O ' 511 i;'j3 r\ <.,. ^7 , O 7 //' >p? > xs~- u /9 ? ? i5~~(j/Pb) i 6 Q,o 0 79 IS so so? 9 si If m 11 j-i S' /si /7 90 )S SI /V S' lo P9 3 $11. UCh > fs;" h // 3 7s 7/ /S sis 19 7 9' i/ 7 > 00 75 1 y 3 9 .9 7, 7S 5 /x X NGC 01344 P P. 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