Document Jrj1D5w45k1XQjMjQXY0qeyd2

INTERNAL CORRESPONDENCE rifii 1 UNION CARBIDE CORPORATION P.G. SOX 579. 4625 ROYAL AVE. ,'/IETALS DIVISION NIAGARA FALLS. NEW YORK 1 4302 To CNarneJ Division Location Area Coov co Messrs. R. J. Kronkbyte J. L. Myers UCC - Metals Division King City, CA Date Originating Oept. Area April 11, 1983 New Product Development Messrs. G. L. Dickson T. J. Kagetsu D. F. Kapral R. 0. Marsten H. B. Rhodes J. B. Rouse F. L. Smith W. C. Thurber i--- Subiect . ' // -tT... ' k___ Asbestos Dust Control Results of NIOSH Air Monitoring Survey of King City Bagging Room Operations Project No. 530-10903 N, ' T" During the week of January 23-30, 1983, NIOSH ran a three-day air monitoring survey of the plant bagging operations. Objectives of the survey, test protocols and operating conditions are discussed in the attached report issued by the writer February 3, 1983. . The fiber count results for March 25, 26 and 27 are shown in Tables I, II and III, respectively. Ceiling value concentrations in the main circuit bagging area ranged from 0.4 to 6.8 fibers/cc for personal samples. Personal ceiling exposures for the RG-244 bagging operator were between 1.1 and 6.6 fibers/cc. Personal time weighted averages (TWA) based on approximately four hours of testing per day demonstrated levels in excess of 2.0 fibers/cc in four separate instances. TWA's for operators in the main circuit bagging room ranged from 0.5 to 3.6 fibers/cc. TWA's for the RG-244 bagger were 1.4 to 3.8 fibers/cc. The high exposures are attributed for the most part to various mechani cal problems evident during the course of these tests; the details of which are covered in the preliminary report appended. However, these tests demonstrate the need for some sort of continuous monitoring program. It would, in my opinion, behoove us to proceed with a plant evaluation of continuous air monitoring equipment as soon as possible. Tom Cooper, project leader of the NIOSH survey team, contacted me March 30th. They have completed the dust counts and their results are consider ably lower than ours. According to Tom, their highest ceiling value was 2.7 fibers/cc and the TWA's were all less than 0.6 fibers/cc. I did not discuss our findings with him. He is sending us copies of their raw data this week. The final report will not be forthcoming for at least another month or two. UCC 001383 Messrs. R. J. Kronkhyte J. L. Myers -2- April 11, 1983 In view of the discrepancies between labs, we recounted several of the more heavily loaded filters. These results are shown in Table IV. Generally speaking, the replicate counts demonstrated correlations with original test results within the accepted limits of variance. With one exception. Sample D-60, the replicate counts were significantly lower than the original count. This sample contained a considerable amount of fine fiber with diameters approaching the visible detection limit at 400X magnification and was very difficult to count. This type of fiber was detected in some of the other RG-244 samples as well. With fine particulate of this nature, every field viewing area has to be scrutinized in detail at several focal planes. Normally, a sample can be counted in 10 to 20 minutes. 3y comparison, it took approximately an hour to count D-60. As you are aware, our fiber does not exhibit the morphology typical of Canadian chrysotile. Coalinga asbestos has a much smaller mean diameter and fiber length distribution. Because of this and the fact that most counting laboratories are not familiar with Coalinga asbestos, their fiber counts are often artifically low. I should point out that it is possible that the NIOSH counts are correct. Prior studies have shown that the variance between simultaneous multiple samples can be quite high. In this instance, however, I think the problem is related to differences in the counting procedure rather than between samples. It would appear that the NIOSH counting lab missed a significant amount of asbestos fiber in some of the samples. BLI:et Attach. CT2. B. L. Inga UCC . 001384 KING CITY AIR MONITORING TEST RESULTS - MARCH 25, 1983 Bagger entered product b in fo r ^ 20 minutes during th is sample p e rio d , RG-244 bagging u n it not working p ro p e rly . Some bag breakage occured d u rin g th is p e rio d . W- uV u LO ro s. o> JO 4o- lO 03 rH <0s>_9 o Cr--M1 LO (H CO CO CM CO 11 lr-oH < Co<CQTo1 'Si' CO LoO ot--4 cr--n4 -M 3i O s. o or* r* r* c o M r-- i o . (TS -a uo ^r r* o CM 4- . "O o CD CD SJ o o ac . 0) 1 1 a *-h r-- s- I-- S_ <9 cu <9 cu V 3 cn r-- o 3 o cn a lo (T3 LO 03 r jo s- jo 3 0) J*S O +> S- T- JO c C3 s_ (O r~ a> <tj C LO o i a. 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S_ cu 03 Q. ns J= C(pC*JL tn <n 03 as 0(tJ3 ja ja 2. <2>U- oo 11 (T3 tO <2CU. 023. <C <D JSZ +J 4O +J t/3 oE O O +J tp2/%aa CO a. <2u. *o rct3 J^ <CTU3 p-- <paT5 4-> p" c 3 03 P* 03 f0tJ3 JO- CM 1 LO 1 o CO 1 C_3 t<o3" o pH . ^UCC 001387 p^. LXOI) CM LO CO LO o1 CJ o CO PLHO. 1 Q1 o rH TABLE IV Sample No. J-36 D-40 D-44 D-60 D-64 UCC REPLICATE FIBER COUNTS Original Count^ 3.1 5.1 6.8 6.6 0.6 (?) Replicate Countv ' 1.3 4.0 6.7 3.4 0.6 Replicate Count1 2.7 6.2 8.1 4.6 0.6 ^^Performed by F. L. Smith - March 11, 1983 (2)performed by F. L. Smith - March 29, 1983 ^Performed by B. L. Ingalls - March 30, 1983 UCC 001388 Niagara Falls, New York, February 3, 1983 REPORT NO. 33-M-4 FILE NO. 530-10903 UNION CARBIDE CORPORATION METALS DIVISION TECHNOLOGY DEPARTMENT - PRODUCT DEVELOPMENT TRIP TO: King City, California DATE: January 23-30, 1983 BY: B. L. Ingalls PURPOSE: NIOSH Monitoring Survey INTRODUCTION NIOSH ran a three day air monitoring survey of the plant bagging operations. The objective of this study is to document effective methods currently in practice for the control of airborne dust and further promote their use in industry. DISCUSSION NIOSH personnel in attendence: Thomas C. Cooper, Mining Engineer (Project Leader) NIOSH, 4676 Columbia Parkway, Cincinatti, OH 45226, Telephone: 513-684-4320 Paul E. Caplan, P.E., C.I.H. Res. INd. Hygienist (address, same as above) Telephone: 513-684-4442 Alfred A. Amendola, P.E. Chief, Materials Porcessing, (address, same as above) 513-684-4224 Pierre L. Belanger, M.S., Industrial Hygienist, NIOSH, DH0W, region IX 50 United Nations Plaza , San Francisco, CA 94102, telephone: 415-556-3781 Test Protocol' Air samples were obtained on bagging personnel in both the RG-244 and Main circuit bagging areas for approximately two consecutive hours in the morning and again in the afternoon of January 25, 25 and,27, 1983. A total of eighteen stationary area locations were also monitored at the same times in the two bagging rooms. NIOSH collected a total of 120 area and 13 personnel samples over the course of the three days. Samples were collected by.Union Carbide simultaneously on the three bagging operators and at five of the stationary area points monitored by NIOSH totaling 47 samples in all. Area sampling locations are shown in attached schematics of the RG-244 and Main circuit bagging rooms. UCC 001389 -2- Test Protocol cont'd NIOSH also conducted tests for hood face-velocities, duct and static pressure measurements and pitot tube traverses of the ventilation systems in the two bagging areas. NIOSH used MSA model G pumps calibarated to a setting of 1,5 l/m. UCC used MSA model G and new Gilian model HF 113T pumps also set at 1.5 L/m. Milliporemembrane filters of 0.8 micron porosity were used throughout. Sample identifications and test information regarding sampling times, locations, and other pertinent data are appended. Photographs were taken by NIOSH of the various test locations and negatives were left with UCC for editing prior to release. ; Operating Conditions January 25, 1983- Weather conditions: temperature low 60`s with scattered clouds and light to moderate winds (5-15 mph). The RG-244 bagging unit was not performing properly during the grave shift resulting in excessive bag breakage. The problem was resolved before testing commenced but some breakage did occur during the day. Pellet cooler broke down requiring approximately 1 1/2 days to repair. Bauer mill seals failed sometime during later part of the grave shift. Both Main circuit and RG-244 products were contaminated with oil necessitating a temporary shut-down and purging of the circuits. The Bauer was bypassed for the remainder of the week while repairs were made. As a result, only RG-244 and SG-103.5 were produced during the monitoring tests. The Black and Stoker packers were used for the main circuit material during the morning of the 25th. Switched to the Auger packer and plastic bags in the afternoon which continued for the remainder of the week. The main circuit bagger went into the product bin during the last 20 minutes of the morning test (sample P-1, 8:05 - 10:01am. January 26, 1983 - Weather cloudy with a slight drizzle in the afternoon. Temperatures ranged from high 50*s to mid 60's. Winds medium to high with gusts 10-30 mph. Some dusting noticed late morning in RG-244 bagging area. A Raymond mill was being repaired and considered a possible source of the problem. RG-244 bagger went inside the bagging unit temperarily (2-5 minutes) during the morning test. (Sample P-3, 8:05-9:56 am). RG-244 rotolouvre drier was not operating properly. Firing unit repeatedly kicking out causing erratic moisture control. Ultimately, it was repaired during the course of the day. The main circuit ventilation duct for the broken bag disposal unit was found to be plugged several feet during pitot tests. A considerable dust cloud was generated in the area for approximately 2-3 minutes while the duct was being cleaned at 3:05 - 3:08 pm. January 27. 1983 - Rain light to heavy during the morning with winds up to 25-35 mph. Temperature 50-550 Cloudy with higher temperatures and intervals of sunshine during the afternoon. RG-244 bagger unit leaking asbestos fines. Considerable dusting in bag room during grave shift; fines on the rafters and floor etc. Windy conditions caused dust swirling- effects in the bag room. Testing was terminated for UCC 001390 approximately 1 1/2 hours while repairs were made to the bagging unit. NIOSH subsequently decided to discard morning samples obtained in the RG-244 area because of abnormal conditions stated. Preliminary Observations Dust and hood velocities measured by NIOSH were found in general to be within design specification limits established by UCC Engineering. NIOSH Comments: In general, plant dust controls and work practices were good, but could be improved in some areas. No serious problems were noted. Suggestions included: 1. A ventilation hood over the RG-244 broken bag disposal unit. . 2. Modification of the air duct pickup system for the main circuit broken bag disposal system to prevent clogging. 3. The addition of plastic closure strips at the openings of the bag shapers and shrink wrap ovens where not already in use. 4. Bar to be installed across RG-244 bagger hood opening to prevent operators from entering the unit during cleaning. 5. Removal of an elbow in the air duct hose to the RG-244 bagger cone to improve flow. 6. Eliminate spillage from RG-244 bag spouts between packer and weighing scale (work practice problem). 7. An enclosure or hood for the RG-244 Micro-Pulverizer equipment (UCC suggestion). 8. Main circuit bagger enclosure exhaust duct slide gate requires some sort of locking mechanism to prevent accidental closing. 9. Exhaust dust catcher under main circuit straightening belt just before shrink wrapping device not working properly. CONCLUSIONS Conclusions are pending completion of the fiber counts and compilation of the test results. At such time, the results of the two laboratories will be exchanged for comparative purposes. ' /jl UCC 001391 <0 I r VO p OC? 0 > a- 04 UCC 001392 O ff*ce UCC 001393 UCC 001394 Fom t U C C /M TIS OII Q 2 -4 /2 A UCC 001395 form: UCC/MTl S -O H -B 2 -4 /2 A UCC 001396 Farms U C C /M Tl S 0 1 1 8 2 4 /2 A * Fums U C C /M T lS -011-8 2 - 4 /2 A *1 .V <0o3 0. 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