Document KJZabvZLvoGZB34RK0Q1BZg8o
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V
Distribution; W. F. Armstrong J. J. Bergin J. G. Burdick R. F. Cope S. A. D' Armond 4---' M. F. Gautreaux R. Herzog C. B. Hunt D. E. Johnson B. P. Pancamo D. E. Park T. R. Robinson W. C. Strader A. 0. Wikman
i
VC4675
ETHYL CORPORATION
INTEROFFICE
To G. L. Ter Haar
Address BRT
I'iiom j. D. Watts
Sviijkct OSHA Parallel Monitoring Summary Baton Rouge Plant
Address BRT/BRP Date 10-27-76
A number of employee complaints registered by the United Steel Workers Union resulted in a comprehensive OSHA survey of the Baton Rouge Plant. The OSHA survey was conducted by a combination of safety and industrial hygiene personnel from the Baton Rouge area office and initiated on August 25, 1976. The fence-to-fence evaluation was completed on September 23. This report will only focus on the industrial hygiene aspects of the investigation.
The results of our parallel monitoring affords the opportunity to recognize potential problem areas. The OSHA industrial hygienists also gave some insight into possible citations based on their observations (not monitoring data). The probable plant areas of concern based on both our data and OSHA comments are summarized below.
OSHA Summary
1. A welder in Central Shops was monitored for exposure to inorganic lead which showed 1.25 mg/m3 (six times OSHA standard). This exposure level grossly exceeded the standard due to incorrect work practices and was pointed out to the OSHA hygienists during the specific sampling date.
2. OSHA pointed out that the proper precautionary signs for potential employee exposure to asbestos fibers are not posted in Central Stores. OSHA 1910*1001 Section (g).
3. There were specific references to the use of asbestos
in the caustic-chlorine cell shop. It is likely that we will
receive citations for not following the Federal Register
regarding the labeling of scrap, waste troughs, etc. and good
housekeeping procedures as stated in OSHA 1910.1001 Sections
(g) and (h).
4. Results of parallel monitoring showed that the sludge utility operator in the Sodium Plant may be potentially exposed to caustic levels in excess of the OSHA standard of 2 mg/m3. Our data indicates an exposure of 2.8 mg/m3;
however, this sampling procedure is based solely on the fact that all of the sodium particulate which was collected on the filter was caustic. The actual caustic 1 vel would be lower.
VC4676
G. L. Ter Haar Page Two 10-27-76
5. All of our personnel monitoring' information from "C" Building shows organic lead concentrations in excess of 0.075 mg/m3. Both actual and potential samples were taken; however, the organic lead levels were very comparable and a citation is probable.
6. Three of five potential samples for organic lead in "D" Building exceeded the OSHA standard. Although these samples ranged from 0.083 to 0.089 mg/m3, there should not be basis for citation since these represent potential expo sures and only exceed the regulations by a minimal amount.
7. Our parallel monitoring data for vinyl chloride monomer shows no problem in PVC. However, OSHA indicated that a citation would be issued due to employees not wearing pro tective garments when entering autoclaves to clean PVC from vessel walls. OSHA 1910*93 Section (h).
8. OSHA also indicated that the eye wash fountains on the plant should have a quick release valve rather than a screw type valve.
According to Mr. James Powell, area director for OSHA, he expects this type of comprehensive survey to minimize the number of plant visits by OSHA due to employee complaints and thereby reduce both Ethyl's and OSHA's time and manpower requirements.
It is anticipated that OSHA will contact Plant Manage ment late this month or early November concerning the closing conference. The results of our parallel monitoring by plant area are discussed in the following attachments.
If you should have any questions or comments regarding this OSHA summary, I will be happy to discuss them.
JDW/crb
Industrial Hygienist
VC4677
OSHA Parallel Monitoring Summary
Table of Contents
Page
I. Central Shops
*
Welding Shop......................................................................................................1
Pump & Gear Shop............................................................................................3
Central Sandblasting ........................................................................... 5
II. Sodium-Caustic-Chlorine #1 Cell Shop.......................................................................................................6 Barium Chloride Pit....................................................................................10 Sodium Tickler Change-out ...................................... ..... 10 Burner Room.........................................................................................................12 Downs Cell Change-out . ..........................................................................12 Sodium Maintenance Shop ..........................................................................14 Cell Bath Grinding Operation..........................................................14
III. Lead Alkyl Area
Drumming Plant...............................................
16
"C" Building ....................................................................................................19
"B" Building....................................................................................................21
C & D Furnaces...............................................................................................23
"D" Building........................................................................................... . 26
IV. Polyvinyl Chloride PVC Reactor Floor.........................................................................................28 Finishing & Compounding ...................................................................... 29
V. Hydrocarbon...............................................................................................................
VC4678
Table of Contents (cont.)
VI. Aerated Lagoon.........................................................................................33 VII. Research & Development..................................................... .... 34
. /
VC4679
I. Central Shops
1
As part of the OSHA Industrial hygiene survey of the Central Shops area, one welder was monitored for exposure to inorganic lead and the other two for welding fumes. An inorganic lead concentration of 1.25 mg/m3 was found for the welder which was attributed to incorrect work procedures. Very low levels of welding fumes (FeO, ZnO, and Ni) were found associated with the work of the other two welders.
***
A wdlder was monitored for inorganic lead exposure in the burning booth while salvaging parts of alloy melt pot .pumps. Due to the accumulation of lead on the equipment and the burning process, smoke and fume were generated. The exposure grossly exceeded the OSHA standard due to incorrect work practices -- positioning himself between the pump and the exhaust vents of the booth while burning. No respiratory protection was worn although a breathing air mask station is available for employee use.
It is recommended that the pump and gear mechanics who are assigned to this job be utilized in turning the pump in order t^o prevent such an elevated exposure from occurring again. Furthermore, the use of respiratory protection could be used as an interim control measure; however, a recent check by Technical Services found the exhaust ventilation in the booth to be more than acceptable to control the fumes.
Two welders were monitored for exposure to welding fumes on 8/30/76. The particulate was collected on 0.8 p millipore filters at a sample rate of 1.75 - 2.0 liters/minute and specific metals were analyzed by atomic absorption spectro photometry. Both welders used number 7024 mild steel rods while building up the inner walls of sodium cathodes.
Following parallel sampling with OSHA, it was understood that iron oxide, zinc oxide, and nickel would be most suspect. Very low concentrations of these metallic components were found in our samples. The results of monitoring are shown in the following table. It was later learned that OSHA would also analyze for chromium, manganese, and copper; we feel that these metals should also be found in trace amounts.
VC4680
2
Date 8/30/76 8/30/76
Central Shops Welding Shop Welding Fume Evaluation
Employee Welder (A) Welder (B)
Sample Time Time Weighted Average (mg/m'*)
Minutes
FeO
ZnO
Ni
361 334
0.105 0.18
0.004 0.003
<0.001 <0.001
OSHA Standards:
FeO
10 mg/m
ZnO
5 mg/m
Ni 1 mg/m
VC4681
3
Pump and Gear Shop
Parallel sampling was conducted with OSHA for air con taminants in the Pump and Gear Shop. Six employees were monitored for exposure to Pb-in-air while working on decontaminated equipment from the TEL Area. These samples showed no hygienic problem in this area.
***
9
Personnel monitoring of the Pump and Gear mechanics was conducted on 8/30 and 9/1/76 for both inorganic and organic lead. The inorganic lead was collected on Gelman glass fiber filters and the organic vapors on charcoal with
subsequent analysis by the dithizone method. The sample rate was approximately 1.5 liters/minute.
On 8/30/76, two mechanics assisted a welder at the burning booth while two other employees worked on rebuilding a sluice pump. Two employees were also monitored on 9/1/76 while rebuilding a Lewis pump for exposure to lead.
Both the sluice and Lewis pumps had been decontaminated
at the Wash Pad and sandblasted prior to reassembly in Central Shops. The inorganic lead values ranged from 0.007 to 0.148 mg/m3 and the organic lead levels from 0.002 to 0.016 mg/m3. The complete results of' sampling are shown in the following tables.'
VC4682
4
Date
Central Shops Pump and Gear Shop Personnel Monitoring for Pb-in-Air
Employee
Sample Time (minutes)
Actual Exposure (mg/mJ)
TWA (mg/mJ)
Inorg Pb
Org Pb
Inorg Pb
Org Pb
/30/76 /30/76 /30/76 /30/76 */l/76 '/1/76 )/l/76
Johnston Ambrose DeBate Edmonston Brooks DeBate Fixed Station
395 374 400 396 445 448 438
0.017 0.014 0.178 0.058 0.007 0.019 0.007
0.003 0.003 0.013 0.018 0.009 0.017 0.010
0.014 0.011 0.148 0.048 0.007 0.019
0.002 0.002 0.011 0.015 0.009 0.016
Standards:
/
Inorganic Pb
Organic Pb
0.2 mg/m^
3 0.075 mg/m
t VC4683
5
Central Sandblasting Two sandblasters were monitored for exposure to silica
during the OSHA visit. Comparison of both of these samples with the calculated standard for the respirable silica frac tion shows very low concentrations on this sample date.
***
As part of the OSHA investigation, two sandblasters were monitored for silica on 8/30/76 at the Central Sandblasting area. Our samples were collected on closed face 0.8 p millipore filters at a sample rate of approximately 1.8 liters/ minute. The analysis was conducted by means of a polarizing microscope using dispersion staining to (1) determine the total quartz present and (2) determine the amount of silica less than 10 p. The sample was collected inside the hood while sandblasting and clipped on the lapel when not sand blasting.
It was found that six percent of the silica was less than 10 p in size. Based on the calculated standard for respirable size quartz of 1.25 mg/m^, our samples showed 0.04 and 0.01 mg/m' TWA. Also> a sandblaster was monitored for exposure to Pb-in-air. Our analysis showed an inorganic lead value of 0.087 mg/m3; however, the organic lead level was unavailable due to lab accident. The employee blasted a Lewis pump, alloy melt pot pump, collector and cell top from sodium, and a sluice pump housing.
VC4684
6
II. Sodium - Caustic - Chlorine
An extensive OSHA evaluation of operations and mainte nance job functions was conducted at the Sodium Plant. Among the chemical agents sampled were (1) asbestos, (2) barium chloride, (3) caustic, (4) welding fumes, (5) total dust, and (6) inorganic lead.
Personnel monitoring for asbestos and inorganic lead was conducted in the caustic-chlorine cell shop. Employee expo sure to barium chloride was evaluated while this compound was added to the brine. The predominant chemical agent monitored was exposure to caustic. The caustic levels were evaluated during the change-out of sodium ticklers and Downs cells. The sludge utility operator was also monitored for exposure to caustic.
Employee exposure to welding fumes was investigated on the second floor of the Sodium Maintenance Shop. Total dust levels were measured during the sodium cell bath grinding operation and samples for inorganic lead were taken during the lead pouring operation in the caustic-chlorine cell shop. All of the chemical agents will be discussed by area in the following review.
Caustic-Chlorine Cell Shop
Personnel and fixed station monitoring for asbestos was conducted on three separate sample dates. Asbestos is handled in the #1 cell shop in the rebuilding of Hooker cells. Asbestos is also washed from the cells using high pressure hoses. The samples were collected on open face 0.8 p millipore filters at a flow rate of approximately two liters/minute. A total of 100 fields were microscopically counted.
Asbestos fibers may not exceed 2 fibers/cc greater than 5 microns in size according to the standard effective July 1, 1976. As a ceiling level, no employee can be exposed to asbestos in excess of 10 fibers/cc. Our results of parallel monitoring with OSHA showed no airborne concentrations of asbestos in excess of either of these standards. However, OSHA implied that citations would be issued due to improper handling and disposal of asbestos waste. The results of asbestos sampling are shown in the attached table.
The lead pouring operation in the #1 shop was also evaluated during the OSHA visit. The rebuilding of four Hooker cells and the pouring into the cell bases was moni tored on 9/9/76. Personnel and fixed station monitoring was conducted for employee exposures to inorganic lead.
VC4685
7
With the increased exhaust ventilation due to the instal tion of a wall fan, the inorganic lead levels ranged from 023 to 0.027 mg/m3 TWA. The attached table shows the -.pling results.
Caustic-Chlorine Cell Shop Asbestos Sampling *
Date
Sample
Sample Time (minutes)
Actual Concentration
TWA (fibers/cc)
Remarks
9/1/76
Cell Mechanic **
205
9/3/76 9/3/76 9/3/76
Cell Mechanic Ceiling Fixed Station
9/16/76
Cell Mechanic **
9/16/76
Ceiling
9/16/76 9/16/76
Ceiling Fixed Station
427 18
466 434
16 17 432
* Millipore Filters (0.8 u) - open face Number of fields counted = 100 Size of field ** 0.003481 mm2
** Employee wore disposable dust respirator
OSHA Standard: TWA = 2 fibers/cc C iling = 10 fibers/cc
0.41
0.09 0.08 0.02 1.8 2.6 2.7 0.04
0.175 0.08
1.63
No bag dumping; operations upset gunk release
North side of vacuum tank
Deposited & wash d 2 cells each
Dumping asbestos into vat
Dumping asbestos into vat
North side of vacuum accumulator
9
Caustic-Chlorine Cell Shop
Lead Pouring Operation 9/9/76
Sample
Sample Time (minutes)
Actual Concentration Inorganic Pb (mg/m^)
Time Weighted Average Inorganic Pb (mg/m3)
Cell Mechanic (A)
Cell Mechanic (B)
Cell Mechanic (C)
Fixed Station (exhaust fan)
425 422 419 422
OSHA Inorganic Pb Standard = 0.2 mg/m3
0.030 0.026 0.029 0.077
0.027 0.023 0.025
VC4688
10
Barium Chloride Pit
Employee exposure to barium chloride was evaluated on 9/1/76 during the addition of this material to the brine. The barium chloride is used to precipitate the sulfate con tent. The operation is conducted only on the Monday, Wednesday, and Friday day shift.
The particulate was collected on closed face millipore filters at a sampling rate of approximately 2 liters/minute with subsequent analysis by. atomic absorption spectrophotometry. The OSHA standard for barium (soluble compounds) is 0.5 mg/m3.
Our personnel monitoring results show a potential employee exposure of 0.05 mg/nr during the 110 minutes of sample time. Based on a time weighted average, a level of 0.01 mg/m3 was calculated which shows good hygiene practice. Normally, an approximate 13,000 pounds of barium chloride is dumped into the brine pit; however, on this sample date only 7,200 pounds was added (50% of normal operation). Spot ventilation measure ments were made using an Alnor, Jr. which showed a more than adequate face velocity on the exhaust tunnel.
Sodium Tickler Change-out
/
Two sodium workers were monitored for exposure to caustic during the changeout of sodium ticklers and tickler drives on 9/1/76. The samples were collected on closed face millipore filters with analysis for the total sodium content by atomic absorption spectrophotometry.
In spite of our sampling method and analysis not being specific for caustic, the calculated employee exposure levels were less than the standard of 2 mg/m3 TWA. This calculation is based on the fact that all of the sodium particulate collected on the filter is caustic (worst case possible). Our monitoring data shows levels of 0.59 and 0.43 mg/m3. The sampling information is shown in the attached table.
VC4689
VC4690
t
11 .
Sodium Plant Tickler Change-out Caustic Monitoring - 9/1/76
Sample
Employee (A) Employee (B)
Sample Time (minutes)
400 399
Exposure Concentration
Na20
NaOH
0.55 0.40
0.73 0.52
Time Weighted Average (mg/mJ)
Na20
NaOH
0.46 0.33
0.59 0.43
OSHA Standard: Caustic (NaOH) - 2 mg/m3
12
Burner Room A sludge utility operator was monitored for exposure to
caustic on 9/1/76. This job function includes the burning of contaminated equipment, poking sludge in the filter area, and filling barrels with sodium sludge for disposal.
The results of our personnel monitoring indicate that the employee was overexposed to caustic (2.8 mg/m3 TWA). This elevated level may have been attributed to poor exhaust ventilation in the burner room. Since the OSHA visit, the exhaust fan is scheduled for weekly cleaning and both Tech nical Services and Industrial Hygiene have found adequate air movement to exhaust the sodium smoke and particulate.
Downs Cell Change-out Evaluation of the cell change-out procedures in the #3
cell room was conducted on the "B" shift of 9/9/76. Three employees were monitored for exposure to caustic during the change-out of cells E36 and F6.
The calculated results based on the total formation of caustic on the filters indicate that all three employees were exposed to concentrations which ranged from 0.4 to 1.4 mg/m3 TWA. Our monitoring data shows no hygiene problem in this area. The sampling data is presented in the attached table.
VC4691
VC4692
Sodium Plant Downs Cell Change-out Caustic Monitoring - 9/9/76
13
Sample
Sample Time (minutes)
Exposure Concentration
Na20
NaOH
Time Weighted Average (mg/m3)
Na20
NaOH
Cell Changer (A)
Cell Changer (B)
Leader
Fixed Station (E36 area)
Fixed Station (F6 area)
431 432 427 137
179
0.34 1.24 0.41
0.44 1.60 0.53
0.31 1.10 0.36 0.22
0.07
0.40 1.40 0.47 0.28
0.08
OSHA Standards: 3
Caustic (NaOH} = 2 rag/m
Na20 (Nuisance Particulate) = 15 mg/m3
14
Sodium Maintenance Shop One employee on the second floor of the Maintenance
Shop was monitored for exposure to welding fumes on 9/1/76. The fume was collected on a closed face millipore filter and analyzed by atomic absorption for specific metals.
Analysis of our filters for iron, zinc, and nickel showed very low concentrations, namely, 0.11 mg/m3 FeO, 0.04 mg/m3 ZnO, and 0.03 mg/m3 Ni. The OSHA standards are 10, 5, and 1 mg/m3, respectively. A noise dosimeter study was conducted on another welder in the shop. According to the OSHA .hygienist, the noise exposure was less than the standard of 90 dBA.
Cell Bath Grinding Operation The sodium cell bath grinding operation was evaluated
by OSHA on 9/7/76. Personnel monitoring for total dust levels was conducted on four operators involved in this periodic operation including the monitoring of the "salt
ms n *
The samples were collected on closed face millipore filters, and analyzed gravimetrically on a Mettler balance. The data from our parallel sampling shows all levels below the OSHA standard of 15 mg/m3 for nuisance particulates as shown in the attached table.
i
VC4693
VC4694
Job Function
15
Sodium Plant Cell Bath Grinding Operation Total Dust Monitoring - 9/7/76
Sample Time (minutes)
Total Dust
-- Time Weighted Average (mg/m3)
Upstairs Oper (A) Upstairs Oper (B) Upstairs Oper (C) * Downstairs Oper "Salt Man"
413 415 327 392 419
3.15 8.7 3.1 2.25 10.0
3 OSHA Standard =15 mg/m
Sample started 1 1/2 hours after OSHA sample
2.7 7.5 3.1 1.8 8.7
16
III. Lead Alkyl Area
The OSHA survey of the lead alkyl area included the drumming plant, all three manufacturing buildings, and two
furnaces. The results of our survey are discussed below by specific area.
Drumming Plant
***
Personnel monitoring of three employees was conducted to evaluate exposures to Pb-in-air in the Drumming Plant on 9/10/76. In addition, three painters were monitored for expo sures to solvent vapors from the paint used to spray and stencil antiknock drums.
The lead monitoring apparatus consisted of a Gelman glass fiber filter assemblage in-line with a glass ampoule packed with activated charcoal for adsorbing the organic lead vapors. The samples were collected at a sample rate of approximately 1.5 liters/minute with subsequent analysis by the dithizone method.
The organic lead values ranged from 0.013 to 0.029 mq/rt?
TWA which showed good hygiene practice. A fixed station sample taken on the second floor of the aviation house showed 0.209 mg/m3 organic lead. The paint vehicles and various other hydrocarbons were found in very low concentrations with the exception of vinyl chloride monomer. Two samples revealed VCM levels between the action level and the OSHA standard of 1 ppm. It is not known whether OSHA will analyze for VCM on their charcoal samples.
VC4695
VC4696
Job
Drumming Plant Personnel Monitoring for Pb-in-Air
September 10/ 1976
Sample Time (minutes)
Actual Exposure Inorg Pb Org Pb
TWA (mg/mJ) Inorg Pb Org Pb
17 Remarks
Drum Fill Oper
Portico Oper Portico Oper
319
309 267
0.033
0.029 0.009
0.022
0.045 0.024
0.022
0.019 0.005
0.015
0.029 0.013
Filled 21 drums, worked portico and stenciled
OSHA standard: Inorganic Pb * 0.2 mg/m3 Organic Pb 0.075 mg/m3
Drumming Plant
Personnel Monitoring for Hydrocarbons September 10, 1976
Benzene
C h lo ro fo rm E tC l
MEK
M e th y l C) P e rch lo r
P ro p a n e T oluene
1 ,1 ,2 TCE
T ric h lo r
VCM
X ylene
Job
Sample Time (minutes)
Painter Lst Class Painter Spot Painter
Units of ppm
335 153 130
w
H H
pH
0.01 0.01 0.01 0.02 0.11 0.7 0.1 0.1
0.37 0.2
0.04
0.09 0.44 0.19 0.34
0.96
0.12 0.11
0.09
0.11 0.17 1.45
0.18 0.76
19 "C" Building
The OSHA survey of our TML manufacturing building was conducted on 9/15/76. Both actual and potential (without regard to respirator use) personnel monitoring samples wore collected in addition to fixed station samplinq. This decision was reached due to Ethyl's implementation plan with the area OSHA office regarding the use of- administrative and engineering controls and a respiratory protection program.
All of the personnel and fixed station samples exceeded the organic lead standard of 0.075 mg/m3. A total of three actual samples were collected on the first, third and fifth floors and a total of two potential samples on the third and fifth floors. The actual exposures ranged from 0.104 to 0.395 mg/m3 and potential exposures from 0.107 to 0.521 mg/m3 on a time weighted basis. The sampling results of "C" Building are attached.
\
\
VC4698
Job Function
"C" Building Pb-in-Air Personnel Monitoring
September 15, 1976
Sample Time (minutes)
Sample Type
Actual Ex|>osure
. (mg/ro-')
Inorg Pb
Org Pb
TWA (mg/m^)
Inorg Pb
Org Pb
Remarks
Ground Floor Oper 3rd Floor Oper
3rd Floor Oper
5th Floor Oper 5th Floor Oper
256 . 439
439
394 441
Actual Actual
Potential
Actual Potential
0.043 0.022
0.019
.0.104 0.024
0.319
0.023
0.114 : 0.020
. 0.117
0.017
0.481 0.567
0.085 0.022
0.170 0.104
0.107
0.395 0.521
Rodded out 2 stills
Rodded out 2 stills
Location
Fixed Station Sampling
,, Sample Time (minutes)
Inorganic Pb
Organic Pb
Ground Floor - east tunnel Third Floor - C7 still Fifth Floor - #12 Scale Tank
454 438 434
0.012 0.011 0.030
0.408 0.098 0.503
Remarks
Poured contaminated EDC sample into sump C8 still leak, C-16 gasket leak
21 r** Building
The Pb-in-air evaluation of "B" Building was conducted in the same manner utilizing actual and potential employee exposures and fixed station sampling. All of our personnel monitoring data shows organic lead levels below the OSHA standard.
The actua1 organic lead samples ranged from 0.045 to O.056 mg/nw while the potential samples had a 0.055 to 0.063 mq/m3 range. The fixed station samples showed organic lead levels of 0.081 mg/m3 and 0.066 on the third and fifth floors, respectively. As a result, our parallel sampling showed good hygiene practice on this Sample date and the results of monitoring follow.
VC4700
Job Function
3rd Floor Oper 3rd Floor Oper 5th Floor Oper 5th Floor Oper
"B" Building Pb-in-Air Personnel Monitoring
September 16, 1976
o
n
22
u
Sample Time (minutes)
Sample Type
Actual Exposure (mg/nw)
Inorg Pb
Org Pb
TWA (mg/m^)
Inorg Pb
Org Pb
Remarks
375 407 367
410
Actual Potential Actual
Potential
0.036 0.042 0.042
0.083
0.058 0.074 0.073
0.028 0.036 0.032
0.064
0.071
0.045 0.063 0.056
0.055
Rodded 1 still
Smooth operation
Location
Fixed Station Sampling
Sample Time (minutes)
Inorganic Pb
Organic Pb
3rd Floor - Desk
434
5th Floor - Between #6 & #8 charge heads
412
OSHA Standards: Inorganic Pb 0.200 mg/m^ Organic Pb = 0.075 rag/m3
0.041 . 0.028
0.081 0.066
Remarks
Disc rupture in "D" Building
23
C & p Furnaces
Personnel monitoring for Pb-in-air and a noise dosimeter evaluation were conducted in the "C" and "D" furnace area on 9/17/76. The "C", "D", and "D2" furnace operators were sampled for exposure to lead and two fixed station samples were also collected in the subject areas. Both the "C",and "D" furnace operators wore a DuPont noise' dosimeter to evaluate their exposures to noise.
In spite of OSHA only collecting potential personnel samples in the furnaces, all of the personnel and fixed sta tion levels were less than the OSHA standards for inorganic and organic lead.. The samples included only slagging of "D" furnace as the "C" furnace was recently started up. The personnel inorganic lead samples ranged from 0.080 to 0.100 mg/m3 TWA.
Two employees were monitored with noise dosimeters and it was determined that the "C" furnace operator had a per missible exposure of 95% and the "D" furnace operator had 61%. If the values had been found to exceed unity, their noise exposures would have exceeded 90 dBA (OSHA standard). The 95% and 61% noise exposures are equivalent to 89.6 and 86.5 dBA, respectively.
These noise exposures are more elevated than would be expected due to the use of an air hammer in the area. The air hammer was utilized to chip runover lead on the furnace floor from the lead scale pot. Another contributory factor to the overall noise level is the periodic operation of the dry hopper vibrator located on the south side of each furnace.
Since these employee noise dosimeter readings approach the current OSHA standard of 90 dBA, it has been requested that the operators be resampled. The dosimeter readings are shown in the attached table.
i
VC4702
VC4703
I
J b Function
"C" & "D" Furnaces Pb-in-Air Personnel Monitoring
September 17, 1976
Sample Time (minutes)
Actual Potential Exposure
Inorg Pb
Org Pb
TWA (mg/raJ)
Inorg Pb
Org Pb
24 Remarks
"C" Furn. Oper "D" Furn. Oper "D2" Furn. Oper
446 443 451
0.108 0.087 0.104
0.064 0.044 0.028
0.100 0.080 0.098
0.059 0.041 0.026
Assisted in slagging "D" furnace
Slagged "D" furnace
Location
Fixed Station Sampling
Sample Time (minutes)
Inorganic Pb
Organic Pb
Remarks
"C" & "D" Furn. South Wall
"D2" Furn. - Dry Feeder Area
440 446
0.049 0.038
0.064 0.034
Only "D" furn. slagged
Job Function
25
"C" & HD" Furnaces Noise Dosimeter Study *
September 17# 1976
% Noise Exposure
Equivalent Sound Level (dBA)
"C" Furn. Oper "D" Furn. Oper
95 61
89.6 86.5
* DuPont Audio Dosimeter 90 dBA = OSHA Standard
VC4704
26 "D" Building
Parallel monitoring for Pb-in-air was conducted in "D" Building on 9/20/76. Due to a lack of OSHA manpower, only potential employee exposures were taken on the ground, third and fifth floors in addition to fixed station samples. A total of five personnel and four fixed station samples were collected.
The building was operating six TML and eight TEL auto claves on this sample date. The potential personnel exposures ranged from organic lead concentrations of 0.054 to 0.089 mg/rn^. The fixed station samples showed levels from 0.064 on the fifth floor to 0.269 mg/m3 on the ground floor (ele vator). The results of Ethyl's sampling are attached.
VC4705
Job Function
Sample Time (minutes)
"D" Building Pb-in-Air Personnel Monitoring
September 20, 1976
Sample Type
Exposure Concentration
Inorg Pb
Org Pb
TWA (mg/irP)
Inorg Pb
Org Pb
Remarks
Ground Floor Oper 3rd Floor Oper 3rd Floor Oper 5th Floor Op r
5th Floor Oper
451 436 426' 392
388
Potential Potential Potential Potential
Potential
0.067 0.033 0.022 0.069
0.038
0.095 0.093 0.093
0.066
0.063 0.030 0.020
0.056
0.071
0.031
0.089 0.084 0.083 0.054
0.057
D-l gas ket leak
Good overall day
Location
Fixed Station Station Sampling (mg/m3)
Sample Time (minutes)
Inorganic Pb
Organic Pb
Remarks
Ground Floor - Elevator
3rd Floor - Desk 5th Floor - #9 Scale Tank 5th Floor - Elevator
451
436 407 336
0.024 .
0.013 0.035 0.023
0.269
0.110 0.064 0.129
"B" Bldg. disc rupture
28
IV. Polyvinyl Chloride Plant
Following a walk-through of the PVC plant to familiarize the processes and employee job functions with OSHA# personnel and fixed station monitoring was conducted on 9/22/76. The one-day evaluation included collecting samples for vinyl chloride monomer and PVC dust.
Two personnel monitoring samples for VCM were taken on the utility and the charging operator. Instead of following the monitoring guidelines as stated in OSHA 1910-93 Section D (1), both potential and actual personnel samples were collected. Only the utility operator represented a poten tial VCM exposure. In addition# two fixed station samples for VCM were stationed on the third floor of the reactor building.
Parallel monitoring for PVC dust was conducted in the Finishing area and at the compounding line. A finishing operator was monitored as he bagged EH 250 resin and the ribbon blender operator on the compounding line was monitored for dust as raw materials were added to the blender.
Sampling Procedure
Personnel exposures for VCM were assessed by collecting approximate 100 minute interval samples over an eight-hour shift. The VCM was adsorbed on 600 mg SKC charcoal tubes at a sampling rate of approximately 50 cc/minute for both the personnel and fixed station sample. Analysis was con ducted by desorption with carbon disulfide and injection into a gas chromatograph.
The PVC dust levels in the finishing and compounding area were evaluated by sampling the workplace air through a 0.8 y millipore filter at a sampling rate of approximately 2 liters/minute. Following gravimetric analysis, the con centrations were compared with the OSHA standard for nuisance particulates which is 15 mg/m3 (total dust).
PVC Reactor Floor
The results of parallel sampling for VCM showed a level of 0.14 ppm associated with the utility operator and 0.3 ppm as an actual exposure for the charging operator on a time weighted basis. The two fixed station samples showed VCM concentrations of 0.82 and 2.54 ppm at B10 and B18 autoclave# respectively. OSHA did indicate, however# that a citation would be issued due to employees not wearing protective clothing when entering the autoclaves.
VC4707
29 Finishing & Compounding
The finishing operator showed a total particulate expo sure level of 0.83 mg/m3, well below the OSHA standard. A total dust concentration of 3.7 mg/m3 was associated with the ribbon blender operator. Although OSHA did not sample for inorganic lead at the compounding line, our analysis showed a potential exposure of 0.3 mg/m3 due to the use of a lead compound in the blend (7042 Natural) as a heat stabilizer. Since this compounding blend is predominantly used, we will be resampling this job function in the near future.
Incidental to the VCM and dust monitoring, OSHA took three grab samples for carbon monoxide in the warehouse area. These detector tube readings showed 15, 25, and 50 ppm inside a tractor trailer during the forklift loading of a PVC resin.
VC4708
VC4709
Job Function
PVC Plant Reactor Building VCM-in-Air (ppm)
Sample Time (minutes)
Sample Type
Exposure Concentration
TWA
30
Utility Oper Charge Oper
108 121 112
59 102
71 48
Potential
Actual
4
0.25
0.22 1
0.05
r
0.13 ^
0.86 ^ 0.43 t-
0.53 J
0.14 0.30
Location
Fixed Station Sampling
Sample Time (minutes)
VCM Concentration
TWA
B10 Autoclave B18 Autoclave
130 99
109 74
99 134
98 75
0.6 0.8 1.3 0.5
? 2.2 4.2
1.0
Remarks
Lab accident on first sample Poor air movement on south end of building
PVC Plant Finishing b Compounding Area
Dust Monitoring * September 22, 1976
31
Sample
Sample Time (minutes)
Actual Concentration
TWA rog/m^
Remarks
Finishing Oper
Fixed Station (Grinder)
Ribbon Blender Oper * *
Fixed Station (Air mask station between blenders)
4 *
447 446 392 384
0.9 1.0 4.5 1.1
0.8
Filled approx. 400 bags
3.7
* OSHA nuisance particulate standard * 15 mg/m^
** Employee wore disposable dust respirator during addition of raw materials; Ethyl monitoring also showed a potential inorganic lead Exposure of 0.3 mg/m3.
VC4710
32
V. Hydrocarbon
A walk-through survey of each of the plants in the Hydrocarbon area was conducted by OSHA on 9/23/76. Each of the chlorinated hydrocarbon processes was discussed, such as the review of raw materials, products, and by-products.
a
As a result of the walk-through survey* no personnel monitoring was conducted. OSHA took nine detector tube readings in the #2 EDC/VCM plant for vinyl chloride monomer. The results of these grab samples are shown below:
VCM Detector Tube Results
Location
Concentration (ppm)
VCM Control Room Furnace cracking area West Quench East Quench HCl/VCM column area D17 tank VCM unit (east side) VCM Rundown area VCM Transfer Pump (load rack)
N.D. * N.D. N.D. N.D. 0.5-0.6 N.D. N.D. 1.8 0.5
'
* Denotes not detectable
i
33
VI. Aerated Lagoon
At the request of the Hydrocarbon union representative, OSHA took a fixed station sample on the downwind side of the aerated lagoon on 9/23/76. There have been occasional employee complaints regarding odors generated from the lagoon.
The organic hydrocarbon vapors were adsorbed on a 600 mg charcoal tube using an SKC low-flow pump at a sampling rate of 50 cc/minute. The analysis was done by gas chromato graphy.
Our results of parallel sampling showed no hydrocarbons in excess of the OSHA standards.
Fixed Station Sampling Results
Location
Sample Time (minutes)
Chemical Component
Concentration .(ppm)
Southwest bank
177
Ethyl Cl Methyl Cl Toluene 1,1,2 TCE Trichlor (1,1,2 TCEE) VCM
1.9 0.3 0.3 0.02 0.7
0.4
%
34 VII. Research & Development The OSHA industrial hygienist toured the R & D lab facilities on 9/23/76. No sampling was conducted, although some ventilation measurements were made on the capture (face) velocity of lab hoods. OSHA also requested to see one of Ethyl's pilot plant projects, being aware of the confiden tiality. It was arranged to have a discussion of the DR-1 pilot plant and its raw materials, products, and waste streams.
f