Document EXkaGwmNV6Rq3kMmzG4Dn4ox

LOUISIANA DIVISION INDUSTRIAL HYGIENE REPORT AN OPERATING UNIT OF THE DOW CHEMICAL COMPANY ^PARTMEKT* CHLOR-ALKALI II TITLE* FILE NUMBER* LAD-CA2-87.01 | DATEi I | MARCH 1f 1987 CA II INDUSTRIAL HYGIENE REPORT FOR 1986 AUTHOR(S) SIGNATURE(S): ____ L^JiaxsSitki REVIEWER'S SIGNATURE: W, E. LEDFORD :.eecs:seb:s. SUMMARY/RECOMMENDATIONS; BIERBBSSIIKV{;bIII1ECSbSSSBEE&-SrC I. summary* THE EMPLOYEES THAT HAD A LIKELIHOOD FOR EXPOSURE IN THEIR JOBS TO CAUSTIC MIST, CHLORINE, ASBESTOS, AND NOISE WERE MONITORED USING APPROVED SAMPLING AND ANALYTICAL METHODS. A NOISE SURVEY OF THE ENTIRE PLANT WAS ALSO CONDUCTED. NO DATA WAS COLLECTED ON HYDROCHLORIC ACID OR SULFURIC ACID BECAUSE HISTORICAL DATA SHOWS NO EXPOSURE PROBLEMS IN THESE AREAS. . CONCLUSIONS AND RECOMMENDATIONS: # RESULTS SHOW BELOW CURRENT EXPOSURE GUIDELINES FOF. ASBESTOS, CAUSTIC MIST, AND NOISE. INITIAL MONITORING FOR NEW ASBESTOS STANDARD SHOWED NO POTENTIAL PROBLEMS. CHLORINE DATA SHOWED A FEW PROBLEMS WITH INSTAN TANEOUS EXPOSURE, PROCEDURAL CHANGES AND ISSUING OF PERSONNEL FULL-FACE MASKS SHOULD CORRECT THIS PROBLEM. THE NOISE SURVEY SHOWED ONE AREA WITH NOISE LEVELS AT 114 DB {GAS TURBINE COUPLINGS). ALTHOUGH INSIDE A HEARING PROTECTION AREA, IT WILL BE EVALUATED IN 1987 WITH RECOMMENDATIONS TO FOLLOW. IN 1987 ASBESTOS, CAUSTIC, CHLORINE, AND NOISE SURVEYS WILL BE CONDUCTED ALONG WITH MONITORING FOR CARBON-TET, A NEW AREA AT CA II. DISTRIBUTION: LOUISIANA DIVISION MIDLAND W. T. AUSTIN, 3601 J. E. HENRY, 3601 C. L. WATTS, 3601 '.XROCB ETr "3 601 % W. E. LEDFORD, 3502-E R. A. GASKA, 3701 R. w. GALLANT, 2306 *M, F. CURRIER, 23 02 E. NEVILL, 3502-E WH. M. BELL, 4701-T L* W. RAMPY, 1803 G. w. ENGDABL, 1803 *s. K. NORWOOD, 1803 *J. E. LEBEAU, 1803 A. w. SHAFFER, 1803 *S. M. GORGACZ, 474 R. E. COOK, 1803 M. G. SWANK, 1803 COVER SHEET ONLY COVER SHEET AND DATA SUMMARY SHEETS ONLY OTHER *D, E. CRAGER, FREEPORT, B-1Q1 *F D. AXE, WESTERN, 471 *G. L. MEIR, EASTERN, STRONGS- VILLE, OHIO 00 CONF tDFN"n RESTRICTED: FOR USE WITHIN THE DOW CHEMICAL COMPANY ONLY INDEX SECTION 1986 INDUSTRIAL HYGIENE SURVEY SUMMARY........................ 1 Data by Hazard................................................................................ 1A Data by Area................................................................................ IB NOISE SURVEY............................................................................................ 2 1986 ACCOMPLISHMENTS & 1987 GOALS AND PLANS................... 3 SUMMARY SHEETS........................................................................................ 4 DO 14P675 CONFTDFNTTAI. 1986 INDUSTRIAL HYGIENE SURVEY SUMMARY It is the responsibility of employers to annually determine employee exposure to potential health hazards in the work ar a and report on the results of all involved personnel. The employee is also to be informed of the toxic and hazardous properties of these chemicals and physical agents, the limits they may be exposed to without danger, the symptoms of over exposure, and what they should do to prevent overexposure. ENVIRONMENTAL HAZARDS MONITORED IN CA II BLOCK Asbestos Caustic Mist Chlorine Hydrochloric Acid Noise Sulfuric Acid TLVorlHG 2 fib/cc>5y 3 2 mg/m Ceiling 1 ppm Ceiling 7 mg/m3 Ceiling 85 db(A) 1 rog/m3 DO CON? ASBESTOS EXPOSURE EVALUATION Explanation of Guidelines and Sampling Method The IHG for Asbestos is 0,2 fibers per cc greater than 5 microns in length. This guideline was changed in mid-1986 from 2,0 fibers per cc. Samples are collected using a Bendix high flow pump calibrated at 2.0 1pm with a 25 mm, 0.8 micron pore size mixed cellulose filter and a 50 mm cowl. Analyses are "performed by an outside lab using NIOSH method 7400A. All asbestos is handled wet at Chlor-Alkali II. Exposure Asbestos has very poor warning properties, and effects from overexposure may appear after a latency period of 20 years or more. Asbestosis, mesothellsma and asbestos corns may result from overexposure. Personnel Monitoring Because of exposure guideline changes, this data will reflect monitoring from January through June (2.0 fib/cc) and July through December (0.2 fib/cc). Data Summary Sheets are in Section 1A. During January through June, nine excursion samples (reflecting pulping jobs) and two 8 hour samples (reflecting routine jobs) were run. Result? showed no problem areas nor any need to change procedures. During July through December, five excursion samples (reflecting pulping jobs) and fourteen 8 hour samples (reflecting routine jobs) were run showing no significant change from previous data collected. Monitoring Date January through June January through June Type Sample Excursion 8 hour ^Samples 9 2 Average Reading 0.02 0.02 Highest Reading 0.03 0.03 July through December Excursion 5 0.014 0.02 July through December 8 hour 14 0.012 0.02 SamplingStrategy Plan Historical data shows great improvements over the past four years due to better operating procedures and better techniques in our housekeeping. Sampling for 1987 will include monitoring of operators on a similar basis with more emphasis on craftsmen performing asbestos related jobs. oo i4?677 CONFIDENTIAL CAUSTIC EXPOSURE EVALUATION Explanation of Guidelines and Sampling Method There is a Celling limit set at 2 mg/m3 for Caustic dust and mist. Samples are collected using a Bendix high flow pump calibrated at 2 1pm. A 25 mm, 0.8 pore size, 3 piece cassette mixed cellulos filter is used. Analysis is done by atomic absorption analyzing for sodium. Exposure Contact with skin or eyes causes severe burns and must be washed off immediately. Inhalation causes coughing and painful nose and throat irritation. Personnel Monitoring As shown on the Data Summary Sheet in Section 1A, eleven (11) excursion samples were caught with all results below the ceiling limit. These samples were taken during peak exposure times and agree with historical data. Area Monitoring Three potentially high exposure areas were monitored with the results being well below current exposure guidelines. Monitoring Type Sample #Samples Average Reading Highest Reading Personnel Excursion 11 0.39 & 6 l74 & Area 3 0.02 0.04 vr** Sampling Strategy Plan Historical data shows improvements in area monitoring due to process changes, while excursion sampling during peak exposure times continues to show exposure levels well within acceptable limits. Sampling for 1987 will include the same basic strategy as previous years. DO 142678 C0NFIDFNTTAL CHLORINE EXPOSURE EVALUATION Exlanatlon_of_Guidel^nes_and_Sam2Mll-Jjill2^ The exposure limit "for Chlorine is a 1 ppm ceiling limit, A ceiling limit is an exposure limit that should not be exceeded for any period of time. Operators are required to carry mouthbit respirators at all. times. These are designed for escape purposes only. If required to work in a chlorine atmosphere, half-face or full-face respiratory protection must be utilized. Samples are collected using a microprocessor data logger with a "Wolcott" nafion membrane chlorine sensor. The data logger has the capability of storing highest instantaneous reading, highest 15 minute average concentration, concentration for the duration of the sample, and elapsed time from start of sample. All probes are calibrated before and after each sample by the Industrial Hygiene Department using metrosonlc Dynacalibrator at various chlorine concentrations. Exposure Chlorine gas is irritating to the eyes, nose, throat, and lungs. At high concentrations there can be a burning sensation to the skin. Personnel Monitoring As shown on Data Summary Sheet in Section 1A, 33 twelve hour samples and 20 eight hour samples were caught showing high exposure levels on eight (8) samples with highest 30 second concentrations. Usage of respiratory protection activates a switch which separates actual exposure from potential exposure. Operating procedures have been updated to specify respiratory protection where needed. Monitoring ^Samples 20 Time Span 13 hour ~ 8 hour TWA Actual/Potential PPM o`.T5/t>. 33 0.11/0.11 Avg. High 30 Sec. Cone. PPM -------- 2715---------- 0.42 Sampling Strategy Plan . Sampling Strategy will continue as in past two years, collecting data from all job classifications. DO 142679 CONFIDENTIAL NOISE EXPOSURE EVALUATION Explanation of Guidelines and Sampling Method A Dupont MK-2 Audio Dosimeter was used to measure employees exposure to noise. The dosimeter meets or exceeds all current requirements established by government agencies in the- United States for personnel audio dosimeters. All noise.measurements were made using an 80 and 90 db(A) threshold level, and an 85 db(A) criterion level. The threshold is, the level that'noise must exceed to be included in the dose calculation and the criterion is the decibel level that will yield a 100 percent dose in eight hours. A 90 db(A) criterion level is an OSHA regulation. Our equipment was set for the Louisiana Division criterion level of 85 db(A). The results were reported as 85 db(A) @100%. . All of the audio dosimeters were calibrated before use with an Audio Dosimeter Calibrator at a sound level of 94 decibels. An area survey of the plant was. also conducted using a Bruel & Kjaer Model 2205 Sound Level Meter calibrated at 94 db(A)(1000Hz). Exposure Prolonged and repeated exposures to levels exceeding 90 db(A) may cause severe damage to the nerves in the inner ear resulting in hearing loss. Personnel Monitoring As shown in the Data Summary Sheets in Section 1A, thirty (30) samples were collected showing no significant changes .Jn noise levels. Since hearing protection is worn in all high noise areas of the plant, the exposure levels are all potential doses. All high noise areas are- marked with Caution signs along with borders painted on roadways where hearing protection is required. Area Survey While there were no significant changes in noise levels throughout the plant, the Gas Turbine coupling area seems to be rising. An evaluation will be done this year with recommendations to follow. All areas showed levels t above 85 db(A). Monitoring - Reported on 85 db(A) @100% ^Samples Average Reading Highest Reading Range 30 64.8 184.8 8.4 - 184.8 Sampling Strategy Plan Since all personnel testing agrees with historical data no changes in monitoring will be made in 1987. The evaluation of Gas Turbine coupling area will be done. 00 14?680 CONFTDFNTTAl SAMPLING DATA SUMMARY ASBESTOS: January through June, 1986 EXCURSIONS LIMIT: 2,0 fibers/cc >5y In length ^SAMPLES AVERAGE READING HIGHEST READING 9 0,02 0.03 DATE SAMPLE SAMPLE DESCRIPTION FIBERS/CC DURATION VOLUME >5 MICRONS (MINS.) (LI IN LENGTH 6-09-86 #06955 OT-pulping cells (434350) 30 57.0 0.02 6-11-86 #06954 OT-filled wagon and pulped cells (433856) 66 118,8 0.03 6-16-86 #06958 OT-pulping cells (434350) 171 290.7 0.02 6-17-86 #06962 OT-pulping cells (434350) 25 42.5 0.02 6-23-86 #06963 OT-filled wagon and pulped cells (433856) 122 192.15 0.01 6-23-86 #06964 OT-pulping cells (434350) 90 189.0 0.03 6-24-86 #06965 OT-pulping cells (434350) 6-24-86 #06966 OT-pulping cells (433856) 72 126.0 0.03 72 151.2 <0,01 DO 1.42681 CONFIDENTIAL SAMPLING DATA SUMMARY ASBESTOS: January through June, 1986 8 HOUR SAMPLES LIMIT: 2.0 fibers/cc >5u in length ^SAMPLES AVERAGE READING HIGHEST READING 2 0.02 DATE SAMPLE SAMPLE DESCRIPTION 0.03 PIBERS/CC DURATION VOLUME >5 MICRONS (MINS.) (L) IN LENGTH 6-24-86 #06967 OT-general cell crew duties and pulping (433856) 435 848.25 <0.01 6-30-86 #06968 OT-general cell crew duties and pulping (434350) 450 765.0 0.03 DO 142682 CONFIDENTIAL. SAMPLING DATA SUMMARY ASBESTOS: July through December, 1986 8 HOUR SAMPLES LIMIT: 0.2 fibers/cc >5y in length ^SAMPLES AVERAGE READING HIGHEST READING 14 0.012 0.02 DATE SAMPLE SAMPLE DESCRIPTION FIBERS/CC DURATION VOLUME >5 MICRONS (MINS.) a> IN LENGTH 7-22-86 #06969 OT-general cell crew duties (434350) 450 900.0 <0.01 7-22-86 #06970 OT-general cell crew duties (433856) 450 855.0 0.02 7-23-86 #06971 OT-general cell crew duties (433856) 435 543.75 <0.01 7-23-86 #06972 OT-general cell crew duties (434350) 435 674.25 0.01 7-24-86 #06973 OT-general cell crew duties (434350) 450 832.0 0.01 7-24-86 #06974 OT-general cell crew duties (434350) 450 810.0 0.02 7-25-86 #06975 OT-general cell crew duties (433856) 510 790.5 0.01 7-25-86 #06976 OT-general cell crew duties (434350) 510 739.5 0,02 11-24-86 #03463 OT-general cell crew duties (434350) 480 816.0 0.01 11-24-86 #03464 OT-general cell crew duties (433856) 460 805.0 0.01 12-18-86 #03474 OT-general cell crew duties including pulping (434350) 490 686.0 0.01 12-18-86 #03475 OT-general cell crew duties including pulping (433856) 490 612.5 0,01 00 142683 CONFTDFNTTAl SAMPLING DATA SUMMARY ASBESTOS: July through December, 1986 EXCURSIONS LIMIT: 0.2 fibers/cc >`5n In length ^SAMPLES AVERAGE READING ' HIGHEST READING 5 0.014 0.02 DATE SAMPLE SAMPLE DESCRIPTION FIBERS/CC DURATION VOLUME >5 MICRONS (MINS.) (L) IN LENGTH 11-25-86 #03466 OT-pulping cells (434350) 30 59.25 0.02 11-25-86 #03467 OT-pulping hells (433856) 50 98.75 <0.01 12-01-86 #03468 OT-filled pulp wagon and pulped cells (433856) 60 117.0 OiOl 12-08-86 #03471 OT-pulping cells (434350) 45 90.0 0.01 12-08-86 #03470 OT-pulping cells (433856) 45 87,75 0.02 CONFIDENTIAL ASBESTOS: July through December, 1986 8 HOUR SAMPLES (Continued) DATE SAMPLE SAMPLE DESCRIPTION 11-24-86 #03465 SOT-Cell Area Operations (433967) FIBERS/CC DURATION VOLUME >5 MICRONS -mma a> IN LENGTH 475 902.5 <0.01 12-18-86 #03476 SOT-Cell Area Operations (433900) 490 735.0 <0.01 DO 142685 00NFTDFNTT81. SAMPLING DATA SUMMARY CAUSTIC EXCURSIONS LIMIT: 2 mg/m3 Ceiling ^SAMPLES 11 Cell Crew Caustic Plant AVERAGE READING 0.39 0.31 0.48 DATE SAMPLE SAMPLE DESCRIPTION 6-16-86 #06956 OT-catching GPL's 6-16-86 #06957 OT-catching GPL' S 12-16-86 .#03469 OT-catching GPL's 12-16-86 #03472 OT-catching GPL's HIGHEST READING 1.43 0.83 1.43 DURATION VOLUME (MINS.) AL1__ 30 63.0 0.05 21 46.2 0.30 32 63.2 0.83 60 118.5 0.06 5-14-86 #06952 SOT-general round-caustic area 45 87.7 1.43 5-13-80 #06953 SOT-general round-caustic area 90 180.0 0.08 6-16-86 #06960 SOT-general round-caustic area 22 48.4 0.79 6-17-86 #06961 SOT-general round-caustic area 12-16-86 #03473 SOT-general round-caustic area 12-19-86 #03477 SOT-general round-caustic area 13 105 45 28.6 0,48 201.6 N/D 86.6 0.28 8-19-86 #06977 SOT-general round-caustic area 90 198 N/D DO 142686 CONFTDENTT Al. CAUSTIC AREA ^SAMPLES 3 AVERAGE READING 0.02 DATE SAMPLE SAMPLE DESCRIPTION 12-30-86 #03478 Middle of Iron cell deck 12-30-86 #03479 South side of bird deck 12-30-86 #03480 Top of T-301 HIGHEST READING 0.04 DURATION VOLUME (MINS.) (L> _ 300 660 0.03 300 636 0.04 300 645 N/D 00 342687 CONFTDFNTTAI, i SAMPLING DATA SUMMARY * CHLORINE (Digital) 12 HOUR SAMPLES LIMIT! 1 ppm Ceiling #SAMPLES AVG. TWA ACTUAL/POTENTIAL PPM AVG. HIGH 30 SEC. DOSE PPM 33 0.04/0.07 2.19 DATE AREA MASTER# TWA ACT./POT. SAMPLE PPM HIGH 30 SEC. CONCENTRATION PPM Shift Supervisors 12-03-86 S.S. 12-22-86 S.S. 12-29-86 S.S. 12-30-86 S.S. 431409 431409 431966 431409 #37 0.1/0.1 #57 0/0 *60 0.2/0.3 #61 0/0 0.2 0.2 10.2 0.1 O.S. 's 12-23-86 S.S. 02-04-86 Board 03-10-86 Board 04-01-86 Board 04-23-86 Board 06-24-86 Board 06-26-86 Board 02-24-86 Cells 03-10-86 Cells Breathing Air Worn 433310 433310 433226 433169 433310 432647 431907 432647 433310 #58 0/0 # 1 0/0 # 8 0/0.1 #11 0.2/0.2 #18 0/0 #28 0/0 #30 0/0 # 2 0/0 # 4 0/0 0 0 0.5 21.3* 0.1 0 0 0.4 0.7 SOT's 06-26-86 06-24-86 06-17-86 04-23-86 04-01-86 03-10-86 Caustic Caustic Caustic Caustic Caustic Caustic 434359 434250 434359 433684 433583 433684 #29 #26 #20 #16 #12 #6 0/0 0/0 0/0 0/0 0/0 0/0 0 0 0.9 0.3 0 0 08-13-86 06-24-86 06-17-86 04-23-86 03-10-86 Power Power Power Power Power 434359 434023 433684 434359 435148 #35 0/0 #25 0/0 #19 0/0 #17 0.2/0.2 # 7 0/0.7 0.5 0 0.8 0.8 1.9 * DO 142688 CONF T DFNT T Al CHLORINE (Digital) 12 hour SAMPLES (Continued) DATE AREA MASTER# TWA ACT./POT. SAMPLE PPM HIGH 30 SEC. CONCENTRATION PPM SOT's (Continued) 06-26-86 Cells 06-24-86 Cells 04-16-86 Cells 03-31-86 Cells 434056 434032 433684 433697 #32 #27 #14 #9 0/0 0/0 0/0 0/0 0.2 0 0 0 12-03-86 08-13-86 06-19-86 04-16-86 03-31-86 Liquefaction Liquefaction Liquefaction Liquefaction Liquefaction 433684 434203 433775 433990 433801 #38 0/0.1 #36 0/0 #22 0.2/0.2 #15 0/0 #10 0.3/0.3 24.2 0 0.8 6.9 1.4 00 142689 conftdfntial SAMPLING DATA SUMMARY CHLORINE (Digital) 8 HOUR SAMPLES LIMIT: 1 ppm Ceiling *SAMPLES AVG. TWA ACTUAL/POTENTIAL PPM AVG. HIGH 30 SEC. DOSE PPM 20 0 .01/0.01 0.39 DATE AREA MASTER# TWA ACT./POT. SAMPLE PPM HIGH 30 SEC. CONCENTRATION PPM Engineers 08-12-86 Liquefaction 08-12-86 Power 12-05-86 Cells 12-11-86 Ecology 12-15-86 Projects 140837 433682 434515 086047 434617 #33 #34 #40 #47 #52 0/0 0/0 0/0 0/0 0/0 0 0.4 0.1 0 0 O.S.'s 12-05-86 12-11-86 12-19-86 12-29-86 12-09-86 12-05-86 12-11-86 12-09-86 12-15-86 12-17-86 12-17-86 Lab Lab Lab Lab Lab PM Crew Cell Crew PM Crew PM Crew PM Crew PM Crew 431684 431684 431684 431684 431684 432844 433940 432844 432844 433196 432844 #41 0/0 #48 0/0 #56 0/0 #59 0/0 #43 0/0 #42 0/0 #45 0/0 #46 0/0 #51 0/0 #53 0/0 #55 0.1/0.1 0.1 0.3 0 0.1 2.9 0 0.5 0 0 0 0.3 O.T.1s 12-05-86 12-09-86 12-11-86 12-17-86 Cell Crew Cell Crew Cell Crew Cell Crew 434350 433856 434350 433856 #39 #44 #49 #54 0/0 0/0 0/0 0/0 0 0 3.2 0 00 142690 CONFIDENTIAL SAMPLING DATA SUMMARY NOISE - TWA LIMIT: Reported on 85 db(A) 0100% TOTAL: ^SAMPLES AVERAGE READING HIGHEST READING RANGE 30 64.8 184.8 8.4 - 184.8 Caustic Area Liquefaction Area Power Area 51.4 39.5 103.7 132.8 156.0 184.8 14.9 - 132.8 15.8 - 156.0 8.4 -- 184.8 DATE SAMPLE DESCRIPTION 85 db(A) 0100% 06-11-86 11-24-86 08-19-86 08-18-86 05-13-86 11-12-86 11-13-86 06-18-86 12-04-86 12-18-86 #8601 #8602 #8603 #8604 #8605 #8606 #8607 #8608 #8609 #8610 Caustic Area - OS - Days Caustic Area - OS - Days Caustic Area - OS - Days Caustic Area t SOT - Nights Caustic Area - SOT - Days Caustic Area - SOT - Days Caustic Area - SOT - Days Caustic Area - SOT - Days Caustic Area - SOT - Days Caustic Area - SOT - Days * 21.0 42.6 90.4 57.4 14.9 132.8 32.8 58.0 38.0 25.8 . 05-13-86 06-11-86 08-18-86 08-19-86 11-12-86 11-13-86 11-24-86 12-04-86 12-16-86 12-18-86 #8611 #8612 #8613 #8614 #8615 #8616 #8617 #8618 #8619 #8620 Liquefaction Area - OS - Days Liquefaction Area - SOT - Days Liquefaction Area - SOT - Nights Liquefaction Area - SOT - Days Liquefaction Area - SOT - Days Liquefaction Area SOT - Days Liquefaction Area - SOT - Days Liquefaction Area - SOT - Days Liquefaction Area - SOT - Days Liquefaction Area - SOT - Days 156.0 63.2 19,8 23.6 22.7 17.0 33.4 24,7 15.8 18.8 06-18-86 06-11-86 05-13-86 08-18-86 11-12-86 11-13-86 11-24-86 12-04-86 12-16-86 12-18-86 #8621 #8622 #8623 #8624 #8625 #8626 #8627 #8628 #8629 #8630 Power Area - SOT - Days Power Area - SOT - Days Power Area - SOT - Days Power Area - SOT - Nights Power Area - SOT - Days Power Area - SOT - Days Power Area - SOT - Days Power Area - SOT - Days Power Area - SOT - Days Power Area - OS - Days 8.4 138.8 184.8 84.6 120.4 139.6 59.8 123.2 89.8 87.4 00 140691. CONFIDENTIAL DO 1 4 2 6 9 2 C O N F ID E N T ! CELLS/LIQUEFACTION AREA 1986 POTENTIAL EXPOSURE DATA SUMMARY ASBESTOS CAUSTIC TLV 2 fib/cc>5y ^SAMPLES AVERAGE HIGH 29 0.016 0.03 3 2 mg/it Ceiling 4 0.31 0.83 RANGE <0.1 - 0.3 0.05 - 0.83 CHLORINE: Liquefaction Operator Cell Crew Cell Operator 1 ppm Ceiling 16 0.19P 1.5P 5 0.06P 0.3P 5 0.14A 0.3A 6 0.35P 1.5P 0 - 1.5 0 - 0.3 0 - 0.3 0 - 1.5 NOISE 85 db(A) @100% 10 39.5 156.0 15.8 - 156.0 <x A = ACTUAL P - POTENTIAL CAUSTIC: Personnel Area CHLORINE NOISE A ACTUAL P POTENTIAL CAUSTIC AREA 1986 POTENTIAL EXPOSURE DATA SUMMARY TLV ^SAMPLES AVERAGE HIGH 2 mg/m3 Ceiling 7 0.44 1.43 3 0.027 0.04 RANGE 0.01 - 1.43 0.01 - 0.04 1 ppm Ceiling 6 0.17P 0.6P 0 - 0.6 85 db(A) @100% 10 51.4 132.8 14.9 - 132.8 dq 142693 OONFTDFNTT CHLORINE NOISE A = ACTUAL P POTENTIAL POWER AREA 1986 POTENTIAL EXPOSURE DATA SUMMARY TLV 1 ppm Ceiling ^SAMPLES AVERAGE HIGH 5 0.57P 1.2A RANGE 0 - 1.2 85 db(A) @100% 10 103.7 .184.8 8.4 - 184.8 <E DO 1 4 2 6 9 4 CO NFIDENT! DO 1 4 2 6 9 5 CONFTOFNTTAl \ tiO(K krt|V 4ia4-*oa0*<*0' Mi) . Readings are dB-A slow response sat*tifig rr vz. --i-sc. N3oiS#^!f vl*\ -- 0 DO 1 4 2 6 9 6 d o im f id f n t ia i. /VMM a *MOW | .(Ml CDS./ e* CM* *<D 1 C A.-A*rit*f. urn' H*&' Jj k,|. * ._ Readings are dB-A slaw response setting /. A^ ^ INDUSTRIAL HYGIENE 1986 ACCOMPLISHMENTS POWER 1. HRU-2 Transition Duct Replaced liner and insulation. 2. Condensate Recovery Gloved condensate dump station to area near D-100. 3. HRU Cascaded Blowdown Removed D-404 & 0-405 eliminating clutter, heat problems and steam in trench. MISCELLANEOUS 1. Hood Evaluations Evaluations were done in 1986 showing low flow problems with hook on north wall. This hood has been downgraded to Class B type. 2. Chemical Exposure Indexes These indexes were instituted in Chlor-Alkali II for all > chemicals. The only chemical meriting review was Liquid Chlorine requiring a review every two (2) years with superintendent and major management attendance. 3. Hazardous Communications Standard This standard was implemented with training of all persons concerning chemicals in areas and in lab. Material Safety Data Sheets on all chemicals are in Shift Supervisor's office and in Lab. A Hazardous Communications Standard Internal Audit was conducted in 1986 showing very good results at Chlor-Alkali II. 4.. Scott Air Packs Retraining was conducted in 1986 by Safety and Training Supervisor, 5. Hearing Protection Retraining was accomplished including proper equipment needed and identification of areas where hearing protection are required. DO 147697 OONFTDFNTTAL RESPIRATORY PROTECTION QUANTITATIVE FIT-TEST The withdrawal from the variance application to the respiratory standard by the Chlorine Institute will mean a greater need to use half-face and full-face respiratory protection. All personnel were scheduled for fit-testing for their choice of respiratory protection instead of continuing to use general supply. The following data is a result of that testing: # Persons Tested on Scott-A-Vista Full-face Masks - 54 Men - 50 Women - 4 # Persons Passing Test - 45 Men - 44 Women - 1 Three people were tested on Comfo-II half-face and passed. There were also four (4) persons not tested. The people passing were issued personal Scott-A-Vista full-face masks along with a carrying pouch or Corafo-II half-face masks and a carrying pouch. The remaining personnel will be tested by the end of the first quarter of 1987 either with Scott's or different equipment. 00 147698 CONFIDENTIAL INDUSTRIAL HYGIENE 1987 GOALS AND PLANS CAUSTIC 1. Extend Vent Header off Venturi Stack Decrease caustic vapors in area. 2. Re-vamp Condensate Dump System Reduce flooding and hot condensate exposure. 3. Eliminate Caustic Problem Areas A. Bird centrifuge leaks B. Sample point for D-312 C. Storage tank drainage Reduce caustic exposure. BRINE. CELLS 1. Install Closed Sample Point for Carb Tower Decrease caustic exposure. 2. Install Better Sample Points for Cell Effluent-Headers Decrease caustic exposure. POWER 1. Replace Silencers in both AWC's . Reduce noise caused by deteriorating equipment. 2. Remodel Chlorinating System for CT-401 Reduce chlorine exposure by less maintenance. 3. Evaluate Noise .Exposure at GT Couplings Evaluation will attempt to produce solution for noise problem in this area. CPC & LIQUEFACTION 1. D-208 & D-209 Dumping Process changes and new instrumentation to reduce (hopefully eliminate) dumping frequency. Reduce chlorine exposure. DO 142699 CONFIDENT! Al 1987 GOALS AND PLANS (Continued) ECOLOGY 1, Clean Oil Skimmer and WP-800 Improved efficiency will reduce hazardous waste exposure. 2, Improve Reliability of Chlorine Monitors A. Install stingers in stack probes B. Modify installation (reducing problem areas) C. Good calibration and maintenance program 3, Improve Oil Storage Area A. Fix leak on oil dumpster - sandblast and repaint .. B. Eliminate as many oil leaks as possible to help with clutter in area Less exposure to hazardous waste. 00 147700 CONFIDENT!At CHLOR-ALKALI II INDUSTRIAL HYGIENE SAMPLING SCHEDULE 1987 Number of Sampl s 1. ASBESTOS A. Cell Crew 6 B. Cell Operator C. Craft- - Excursions corrected 10 ' s Occurs 2. CAUSTIC A. Craft Excursions B. GPL Excursions C. General Caustic Area Round 5 5 5 D. Area Samples 6 3. NOISE - 8 HOUR TWA A. Craft B. Power Operator C. Caustic Operator D. Liquefaction Operator .. . . 12 12 12 ' 12 4. CARBON TET A. Liquefaction Operator 5 B. Carbon Tet Area 5 5. CHLORINE A. Operators and Area Samples (collected by IndustrialHygiene Dept.) .1`OD DO 147701 CONFIDENTIAL. FILLED IN BY Dale Crochet *>R# QQ27-Q713__________ PT.ANT CA II BLOCK 3601 CHEMICAL Asbestos MINIMAL DETECTABLE LIMIT AND UNIT " JOB NO. CLASS PERSONNEL.EXCURSIONAREA *PT TWA NO. ** EXCUR. NO. tt EQ. BASIS' $AKP. AVG. HIGH C DURATION SAMP. AVG. HIGH c SAMPLE DURATION IHG 2.0 flb/cc>5u 0.01 fib/cc>5p NO. SAMP. AVG. HIGH c 02 C 11 Crew 30 min 2 0.02 0.02 < 02 Cell Crew 02 Cell Crew 02 C 11 Crew 02 Cell Crew 70 min 90 min 120 min 170 min 3 0.02 0.03 1 0.03 0.03 1 0.01 0.01 1 0.02 0.02 C<\ h3i-N<\ 2UJ t-s yC-i -- C 2Ll a 02 Cell Crew 8 hr 2 0.02 0.03 ' "PROTECTIVE EQUIPMENT: CD MOUTHBIT (2) FULL FACE (3) half FACE OR DUST (4) AIR SUPPLY (5) HEARING PROTECTION COHMENT^^ise reverse side) LH:sb IH-2 (12/86) F0RM1 FILLED IN BY noiP Prnnhpt .........`.i >i. l.-.i.i DR# QQ27-Q713___________ k. :i , i. .`.t, j,;n, IHG 512 fib/cr.>5u` PI imt r*n TT BLOCK ------------------- CHEMICAL Ash^tns ' MINIMAL DETECTABLE LIMIT AND UNIT 0.0l'"iib/cc>5p JOB NO. CLASS PERSONNELEXCURSIONAREA PT TWA NO. EXCUR. NO. ** SAMPLE NO. * EQ. BASIS SAMP. AVG. HIGH C DURATION SAMP. AVG. HIGH C DURATION SAMP. AVG. HIGH C 02 Cell Crew 30 min 1 0.02 0.02 - 02 Cell Crew 02 Cell Crew 02 Cell Crew 45 min 60 min 8 hr 12 0.01 0.02 3 0.01 0.02 1 0.01 0.01 CH N2 a n H! c hz cc e -- 03 Cell Area 8 hr 2 <0.01 <o.o: ' PROTECTIVE EQUIPMENT: wCOtWENTS^fuse revers (1) MOUTHBIT side) (2) FULL FACE [3) HALF FACE OR DUST (4) AIR SUPPLY %LH:sb_ IH-2 (12/86) FORM! (5) HEARING PROTECTION # FILLED IN BY DuIp HrnfthPt DR# 0007-9914___________ pLANT nA II BLOCK 3fiQ1 CHEMICAL Caustic MINIMAL DETECTABLE LIMIT AND UNIT 0.01 mg . IHG 2 mg/m0 C PERSONNELEXCURSIONAREA JOB . NO. CLASS *PT WA NO. * EXCUR. NO. EQ. BASIS SAMP. AVG. HIGH C DURATION SAMP. AVG. ** HIGH C SAMPLE NO. DURATION SAMP. AVG. ' HIGH ( 02 Cell Crew 30 min 3 0.39. 0.83 .J1. 02 C 11 Crew 0 min 1 0.06 0.06 <r i--: O fNZ ft Ll: 03 Caustic P: t 03 Caustic P: t 15 min 45 min 2 0.63 0.79 2 0.85 1.43 * Li_ CZ ac c 03 Caustic P: t 90 min 2 0.04 0.08 03 Caustic P' t 105 min 1 <o.o: <0.01 20 Area 300 min 3 0.02 0.04 - PROTECTIVE EQUIPMENT: (1) HOUTHBIT (2) FULL FACE (3) HALF FACE OR DUST (A) AIR SUPPLY (5> HEARING PROTECTION COMMENT;^use reverse side) LH:sh^ IH-2 (12/86) FORM! t:.titxi : i;.u j.uj;:; PILLED IN BI Dale Crochet PLANT CA BLOCK 3601 CHEMICAL Chlorine .tu:i c. i.n 1.1: iL.U. 1 DK# OOQ6-7B34-. IHG 1 DDm C MINIMAL DETECTABLE LIMIT AND 0NJBkCk05ppm JOB NO. CLASS PERSONNEL *PT TWA NO. EQ. ' BASIS SAMP. AVG. HIGH ** C EXCUR. DURATION EXCURSION NO. SAMP. AVG. HIGH * C SAMPLE DURATION AREA NO. SAMP. AVG. ft] HIGH ( 05 Shift Supv 1 12 hr 4 0.07 0.2 04 Alt Shf Sup T 12 hr 1 0 0 04 Board Oper 4 12 hr 6 0.03 0.2 04 Cell Oper 1 12 hr 2 0 0 ... m ^<t CH is z c"syi Cu.: c IzL. cc c 03 Caustic Pit 1 03 Power Plant 1 03 Cell Area 1 03 Liq. Area 1 12 hr 12 hr 12 hr 12 hr 6 5 4 5 00 0.04 0.2 00 0.1 0.3 26 Engineer 1 8 hr 5 0 0 28 Lab 1 8 hr 5 0 0 04 Cell Crew 8 hr 1 0 0 04 PM Crew 8 hr 5 0.02 0.1 02 Cell Crew 1 8 hr 4 0 0 PROTECTIVE EQUIPMENT: <1) MQUTHBIT (2> FULL FACE (3) HALF FACE OR DUST (4) AIR SUPPLY (5) HEARING PROTECTION &COMMENT^ppse reverse side) LH:s^ IH-2 (12/86) FORM)  4i (AH* . 1.4 . .H .. FILLED IN BY Dale Croch t PUNT CA II 'BLOCK 3601 CHEMICAL Noise DR# 9086-8508 IHG85 db(A) MINIMAL DETECTABLE LIMIT AND UNIT & t % JOB NO. CLASS PERSONNEL EXCURSION AREA PT TWA NO. * EXCUR. NO. * SAMPLE NO. EQ. BASIS SAMP. AVG. HIGH C DURATION SAMP. AVG. HIGH C DURATION SAMP. AVG. HIGH t 04 Caustic Ar 8 hr 3 51.3 9Q.4 04 Liq. Ar a 5 8 hr 1 156 .0 156.0 04 Power Area 5 8 hr 1 87.4 87.4 03 Caustic Ar 5 8 hr 7 51.4 L32.8 v fc--5 C (-- NZ St o D cz cc c 03 Liq. Ar a 5 8 hr 9 26.6 63.2 03 Power Area 5 8 hr 9 105.5 L84.8 ' - PROTECTIVE EQUIPMENT: CD HOUTHBIT (2) FULL FACE (3) HALF FACE OR DUST (4) AIR SUPPLY (5) HEARING PROTECTION COfWENT^j^ua reverse side) LH:s^ IH-2 (12/86) F0RM1