Document LpwwDG4YM4R6yzQ1oV3L4nqO5

F>R&i /98^ fc ^ MaMHHUli Ih'TYSTPIAL HYGIENE SUMMAPY - S. W. Ellis L-5C-A TCPY -- Tdg7^TTo The css c.hrcnctography instrument dedicated to Industrial Hygiene analyses was out of service from December 20, 1981 to February 1, 1982 due to inadequate hydrogen pressure to the instrument. A. COD was completed on February 1, 1982 which increased the pressure from 12 psi to 60 psi. The instrument was returned to service and has operated without problems. The I/H-coordinator provided technical assistance curing installation and followup and the I/H analyst assisted with the installation, check-out and start-up. "SAFETY IS MY RESPONSIBILITY" DUP 0814451 Dv 009809 HIGH DENSITY REPORT FIRST QUARTER 1982 INDUSTRIAL HYGIENE SUMMARY - S. W. Ellis, cont'd LABORATORY - BLDG. 550 High Density Alathon samples from the steam stripper are devolatilized in the lab with a roll mill at 165C. Area and personal monitoring was conducted to determine analyst exposure levels to hexane, octene and toluene. Hexane was 0.10 ppm (8 hr. TWA), TLV = 100 ppm (8 Hr. TWA), octene was 0.001 ppm (8 hr. TWA), P.O.L. = 100 ppm (8 hr. TWA) and toluene was 0.002 ppm (8 hr. TWA), TLV = 100 ppm, (8 hr. TWA). This data indicates that the potential for exposure to unsafe levels is unlikely. Periodic spot monitoring will be conducted on a 12 month frequency in the future. GENERAL The analytical procedure used prior to January 1, 1982 in the Alathon area for vinyl acetate monitoring was determined unreliable. The vinyl acetate hydrolyzed due to humidity and polymerized on the uninhibited*charcoal. Also an external standard was used. A new procedure was developed and put into service which eliminated the unreliable aspects. The sample is collected on charcoal inhibited with hydroquinone to prevent polymerization through a drying agent. An internal standard is used to improve the accuracy of the procedure. "F" UNIT TASK MONITORING FOR VINYL ACETATE Fourteen tasks were monitored; forty-one samples were taken. Sufficient data has not been obtained using the new vinyl acetate analytical procedure to make a final conclusion as to possible exposure above the 8 hr. and 12 hr. TLV of 10 ppm or the short term exposure limit (maximum 15 minutes) at 20 ppm. One task, changing a hyper cylinder, gave the highest result of 5 ppm vinyl acetate. Based on the duration of the task, 3.08 hrs, the actual 8 hr. TWA would be 1.9 ppm which is well within control. Task monitoring results while changing a recycle compressor cylinder indicated that the highest 8 hr. TWA exposure would be 3.3 ppm vinyl acetate. The remaining results were less than .5 ppm vinyl acetate 8 hr. TWA. Data obtained to date indicates that the possibility of exposure above safe limits is remote but additional monitoring will continue to verify this. While personnel monitoring results show low exposures, there are several emission sources which are of concern from a short term exposure standpoint and have been monitored to ouantify the problem. '`SAFETY IS MY RESPONSIBILITY" DU 009810 DUP 0814452 HIGH DENSITY REPORT - FIRST QUARTER 1982 "F" UNIT TASK MONITORING FOR VINYL ACETATE - COnt'd The rear seals on #1 and #2 extruders allow ethylene and vinyl acetate to leak to the atmosphere. To prevent fires, steam is placed on these seals. Quantitative monitoring results using charcoal tubes or the miran infrared analyzer have been unsatisfactory because of the high level of moisture present. The new procedure (specific for vinyl acetate) eliminates the interference from moisture. In all, samples were taken during three periods of high VA copolymer production. Levels as high as 211 ppm were detected versus a short term exposure limit of 20 ppm. Generally, the higher readings were found between the extruders. Until engineering solutions can eliminate these elevated concentrations, this area has been barricaded and respirators are required for entry. On January 26 and 27, 1982 five sets of monitoring were done while producing 18% vinyl acetate copolymer. The monitoring pumps were positioned four feet from the seal and three feet above the floor on the east and west side of each extruder. Data are summarized in Table I. From February 11, 1982 to February 24, 1982 during a campaign of vinyl acetate copolymer ranging from 2.5% V.A. to 18.0% V.A. monitoring was done at the same positions as Table I. Data are summarized in Table II. From March 17, 1982 to March 20, 1982 during a campaign of vinyl acetate copolymer ranging from 8.9% V.A. to 18.0% V.A. monitoring was done at three positions on a centerline between #1 and #2 extruders. #1 position was 10 feet to the rear of the seals, #2 position was in a line with seals - 10 feet from each seal and position #3 was 8 feet to the front of the seals. Data are summarized in Table III. The exposure limits for vinyl acetate are as follows: ACGIH TLV = 10 ppm 8 hr. TWA ACGIH STEL =20 ppm MAX 15 Mins. DUPONT AEL = 10 ppm 8 hr. TWA DUPONT AEL =10 ppm 12 hr. TWA DUP 0814453 `'SAFETY IS MY RESPONSIBILITY" DU 009811 HIGH DENSITY REPORT FIRST QUARTER 1982 TABLE I DATE TIME PRODUCT POSITION - V. A. ,ppm WIND RATE # lE #1W #2E #2W SPD/DIR 1/26/82 0815-115 VAX3170SB 822RPM 2 12 1 1 12N 1/26/82 1115-1415 VAX3170SB 822RPM 4 56 10 2 12E 1/26/82 1415-1715 VAX3170SB 822RPM 9 56 57 3 10ESE 1/27/82 0815-1245 VAX470 931RPM 5 12 78 1 5E 1/27/82 1245-1545 VAX470 931RPM NO 17 90 1 5E RESULT DUP 0814454 "SAFETY iS MY RESPONSIBILITY" DU 009812 HIGH DENSITY REPORT FIRST QUARTER 1982 TABLE II DATE TIME PRODUCT 2/11/82 0815-1115 A-2650 2/12/82 0845-1145 A-3445 2/12/82 1145-1500 A-3445 2/14/82 0800-1100 VAX3120 2/14/82 1215-1515 VAX3120 2/17/82 0830-1130 VAX760S 2/17/82 1130-1445 VAX760S POSITION-V. A. , %V.A RATE #1E #1W #2E 2.5 1148 1 5 1 3.5 1258 1 3 3 3.5 1258 1 5 24 7.5 1150 5 7 18 7.5 1258 6 8 35 9.3 1258 17 3 95 9.3 1154 20 5 96 2/13/82 2200-0100 2/14/82 0100-0400 2/24/82 1100-1230 2/24/82 1230-1400 2/22/82 0800-1100 2/22/82 1100-1300 2/22/82 1300-1600 VAX770 9.5 VAX770 9.5 VAX3135SB 12.0 VAX3135SB 12.0 VAX550 VAX550 15.0 15.0 VAX3174 18.0 1258 1258 931 931 1050 991 866 4 10 2 21 24 24 73 74 77 75 13 65 73 123 141 126 2/22/82 1600-1900 VAX3174 18.0 800 1 3 71 2/22/82 1430-1600 VAX31705HB 18.0 931 4 5 211 WIND ppm SPD #2W DIR 1 7E 1 6NNE 3 9NW 1 9E 1 5E 1 10 SW 1 7SW 15S ' 3 3ESF. 1 4SE 1 9SW 1 8SSE 1 5NW 1 4S 1 5SSW 8S 1 8S 1 10S "SAFETY IS MY RESPONSIBILITY" cO -o fc yi <n DU 009813 HIGH DENSITY RFPORT - FIRST QUARTER 1982 TABLE III DATE TIME 3/17/82 0945-1300 3/18/82 1255-1555 3/19/82 0830-1130 3/20/82 0800-1100 PRODUCT %V. A. VAX3128 8.9 VAX3130 12.0 VAX565 15.0 VAX3170SB 18.0 RATE 1258 1258 1200 981 POSITION-V.A. ,ppm WIND #1 #2 #3 SPD/DI 5 17 9 15SE 9 21 11 7S 3 19 20 15S 8 25 17 5SSE "SAFETY IS MY RESPONSIBILITY' cO TJ O 00 ft oa>t DU 009814 HIGH DENSITY REPOFT - FIRST QUARTER 1982 "J" UNIT During the construction of "J" Unit, the original intent was to use insulation that did not contain asbestos. Inadvertently some asbestos tape was used to insulate -steam lines, mainly tubing. A program was begun in November 1981 to replace all asbestos tape with calcium silicate insulation. The pipe bridge, the catalyst preparation area and the pumping, purificationand compression areas are now classed as non-asbestos areas. It is anticipated that the reaction area will be completed by June 1, 1982. The remaining areas will be completed as time permits. The I/H coordinator will follow the program to verify its completion. DUST MONITORING Area monitoring around the absorbers and bag filter area was conducted twice using a GCA-RDM 101 Dust Instrument while probing absorbers. On March 20, 1982 28 samplings,averaged 0.39 mg/nr total dust. Maximum reading = 2.9 mg/nr total dust. On March 22, 1982 32 samplings averaged 0.42 mg/nr total dust. Maximum reading = 3.4 mg/m"* total dust. All results were below the TLV of 10 mg/nr, however, monitoring will continue until enough data is collected to indicate dust exposure is at a safe level on a statistically significant basis. Personal monitoring was conducted for dust and hydrocarbons during the absorber probing task- On March 20, 1982 three (3) samplings averaged 0.39 mg/nr total dust, and the average hexane concentration was 0.04 ppm. ,Gn March 22, 1982 three (3) samplings averaged 0.31 mg/nr and the average hexane concentration was 0.01 ppm.. The dust concentration was well below the TLV of 10 mg/nr and the hexane concentration was well below the TLV of 100 ppm. Personal monitoring will again continue until data indicates exposure is at a safe level. Area monitoring was also conducted while filling the absorber. Fifteen measurements averaged 5.57 mg/nr and the maximum was 17.4 mg/nr. The area is normally unoccupied during this operation. A dust respirator will be required when entering the area during this operation since the TLV of 10 mg/nr was exceeded. Monitoring will continue. CENTRAL SHOPS - BLDG. 4 The relief valve testing facility is presently located in the open shop. Impact noise above 180 dBA can be generated when relief valves are tested. The TLV for this category of noise is 140 dBA. DUP 0814457 "SAFETY IS MY RESPONSIBILITY" DU 009815 HIGH DENSITY REPORT - FIRST QUARTER 1982 CENTRAL SHOPS - BLDG. 4 - cont'd V The Engineering Service Division has provided the enclosure design criteria and Victoria Plant Engineering Division is providing the design package. Completion is anticipated during the third quarter. At 140 dBA, this job will still present aVshock noise pulse for the entire shop and procedures - currently in place'to warn personnel of a test will have to be maintained in force after the new installation is complete. The potential for welder's exposure to welding fumes above the TLV exists in the welder booths due to poor ventilation. A COD to provide a spot fume removal system for 12 of 21 booths has been approved. The fans and snorkles have been received. Installation of snorkles and fans will begin in June 1982. Construction will fabricate and install the new duct. Project completion is anticipated by the end of the third quarter. After the project is completed, a comprehensive monitoring program will be conducted to verify that welders are being protected from exposure to metals fumes above the safe limits. One brazing job, brazing cast iron, was monitored for four ' hours for metal fumes. All results were well within exposure limits. Data are in Table V. Additional monitoring will be conducted to verify that welders are not subjected to metal fumes above the safe limits while brazing. Brazing is done very infrequently, so it is anticipated it will take 18 months to complete the program. DUP 0814458 "SAFETY IS MY RESPONSIBILITY" DU 009816 HIGH DENSITY REPORT - FIRST QUARTER 1982 Element Area Sample ma/m3 V Personal Sample mg/m3 TLV ng/m3 Aluminum Boron Calcium Chromium Copper Iron Magnesium Manganese Nickel Silicon Titanium Z inc 1.48xl0-5 6.36xl0~5 1.75X10-5 3.18xl0-6 6.89xl0~4 1.33xl0-3 5.83X10-6 3.39 xlO-5 5.3xl0-6 3.18X10-4 3.18 xlO-6 2.54 xlO-4 1.3xl0-8 2.6xl0-8 6.5xl0-9 2.6xl0-9 5.2xl0-9 9.36 xlO-7 6.5 xlO-9 2.6 x 10~8 0 3.12xl0"7 1.3xl0-8 2.6xl0-7 10 10 2 0.05 0.2 5 10 1 1 5 10 5 DUP 0814459 "SAFETY IS MY RESPONSIBILITY" DU 009817 H*gTar h>m* t-nsai-.--S Li .s ..... ,1 - ii > itijriHjmiiiifc^i..iiii^iiiiialiif HIGH DENSITY REPORT - FIRST QUARTER 1982 PAINT SHOP - BLDG. 31 A noise survey of the paint spray booth was conducted on March 9, 1982. The average of 9 measurements was 91.3 dBA, 4.3 dBA above the TLV of 87dBA. This required that the booth be made an ear protection required area when the blower is in operation. An engineering study will be conducted to determine the feasibility of reducing the noise level below 87dBA. Data are in Table IV. DUP 0814460 `SAFETY IS MY RESPONSIBILITY" DU 009818 I Jft*r Jfe.tr . IS fctT CARPENTER SHOP .PAINT... BOOT.H ` Readings are in d tlv is 87dBA DUP 0814461 DU 009819 HIGH DENSITY FEPOFT FIRST QUAPTFP 1982 ELECTRICAL - INSTRUMENT The Evironmental Protection Agency, Region VI, conducted an unannounced inspection of the eight electrical transformers and 275 capacitors that contain polychlorinated biphenyls on January 7 and 8. No violations were observed. NECESSITY COMONOMER COLUMN TAILS OCTENE RECOVERY - G. J. Snyder Revisions were made to improve control, alarms and interlocks on the CMC tails octene recovery system. 1. Level control of the separator was switched to the makeup fuel oil valve coming from Nylon instead of the effluent tails line valve which flows to the Nylon boiler. This change was required because CMC tails now flows directly to the boiler and is regulated by Nylon personnel. When the CMC tails storage tank is returned to service the controls will be switched back.Authorization to reactivate the storage tank has been ^ obtained and work is in progress. 2. High level alarms and interlocks were added to the CMC tails recovery separator and condenser. These changes help prevent carrying fuel oil over to the flare header system. 3. A proposal to improve temperature control of the fuel oil supply coming from the "day" tanks in the Nylon area has been made. This change will provide alternate steam control valves to match the small flow of fuel oil used in the "J" Unit CMC tails system. The existing large valves are sized to handle large fuel oil flows for boiler operation. FLOW ACCOUNTING - T. R. Arnusewicz Several changes have been made to the "J" Unit computer to improve our process control and accounting. A discrepancy between make-up monomer flow and indicated flow to reaction (,'v-3-10%) has been corrected using an empirical relationship. This discrepancy is thought to be caused by piping configurations. DUP 0814462 "SAFETY IS MY RESPONSIBILITY" DU 009820