Document M4k9Eg0o7z90p9a13rKrgB2Ey
*
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: August, 1986 Date of Report: Sept. 29, 1986
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results CHEMICAL
< PEL NO. X
>PEL (OVEREXPOSURES) NO. %
VCM Lead Total Particulates
84 97.7 21 95.5
4 100.0
2
1 0
2.3
4.5
0.0
Overexposures
JOB CLASS
EXPOSURE
SOURCE
General Mechanic
1.2 ppm, VCM
Employee overexposed while changing a gasket on #5 compressor In the VCM compressor shed.
General Mechanic Compounder
2.4 ppm, VCM
* 45.6 Micrograms
Lead/MT***
Employee overexposed while blanking out 744 reactor In preparation for maintenance.
Employee overexposed while charging Line III blenders. The exact cause of his overexposure has not yet been determined.
* Respiratory protection was worn. ** Respiratory protection was not worn.
II. EMPLOYEE ANNUAL HEALTH TRAINING
Preparations, including a class outline, were begun to conduct employee annual health training during September. The training will Include OSHA required instruction related to VCM, lead, asbestos, noise and respiratory protection.
III. MAINTENANCE PERSONNEL LEAD EXPOSURE
The Maintenance worker lead dosimetry program was begun. The measurements, using the same protocols as with routine, Compound/Dry Blend personnel lead dosimetry, are being made as maintenance work within potential lead exposure areas of the Compound Department is performed. The results for the month are as follows:
A
VAB.0001040140
Industrial Hygiene Monthly Report Page 2
III. MAINTENANCE PERSONNEL LEAD EXPOSURE - Continued
Job Class
TWA
Result
^
(Micrograms Lead/MJ
PEL (Micrograms Lead/M
General Mechanic
7.1
47.1
General Mechanic
6.9
47.1
General Mechanic
<. 4.4
47.1
IV. SHORT TERM VCM EXPOSURES
Three, short-term VCM exposure measurements were made during the changing of old and new unit RVCM filter pack filters. The measurements were made with REAL "Minlmonltors" worn by two operators ("A" and "B11, below) as they changed the old unit filters and by a third operator ("D"), who changed the new unit filters. All three wore respiratory protection, as required, during the work.
Operator
A *
B
Equipment Old Chit RVCM Filter Pack Old Uhit RVCM Filter Pack
Sanple Time (Min.)
19.0
19.0
m Result fa"- roo
<-0.1
6.1
Wind Conditions
N to S, 5 MPH
N to S, 5 MPH
C
New Unit RVCM Filter Pack
10.0
362.2
N to S, 5-10 MPH
* Operator "B" was also wearing his regularly scheduled VCM dosimetry badge, the 8-hour TWA result amounting to 0.7 ppm, VCM.
A concurrent area survey was made In each case, using an HNU "Photoionizer". During the old unit work, an Initial concentration of only 5-10 ppm, VCM was measured next to the filter pack head when It was first opened. This concentration dropped to 2-3 ppm within two minutes with no detectable amounts being found beyond fifteen feet south of the work.
During the new unit work, water interference with the HNU prevented an initial measurement at the filter pack head. However, the amount of VCM present was greater, detectable amounts being found as far as thirty-five feet south of the filter pack throughout the work.
More samples are planned.
A
Jerald V. Uptaln
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JF, JWW, DWH, PJK, WFH, TFL, VEM, RAF, AHS, CWT Tom Grumbles, J. R Drumwrlght, M.D. - Houston
VAB.0001040141
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: July, 1986 Date of Report: Sept. 16, 1986
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
>PEL (OVEREXPOSURES) NO. X
VCM Lead Total Particulates
81 100.0 17 85.0
9 100.0
0 3 0
0.0
15.0
0.0
Overexposures
JOB CLASS
EXPOSURE
SOURCE
Color Weigh Compounder
38.6 Mlcrograms Lead/M
* Color Weigh Compounder 211.6 Micrograms
Lead/M3
Color Weigh Compounder
* 79.9 Micrograms
Lead/M3
Employee overexposed while weighing up small amounts of Cyastab 523 for Compound Line V in the Color Weigh Room. The employee's recent overexposures, including the two below (extra samples taken during investigation), have been related to work practice changes caused by Line V startup. Corrective measures are being taken.
Employee overexposed while weighing up Cyastab 564 in the Color Weigh Room.
Employee overexposed while weighing up Cyastab 564 in the Color Weigh Room.
* Respiratory protection was worn.
II. 0SHA ASBESTOS STANDARD
The following steps have been taken to comply with the new OSHA asbestos standard:
- Two kits were ordered to allow conversion of two, existing 3M airhats to "high efficiency".
~ A supply of asbestos hazard warning labels was ordered and received.
A
VAB.0001040142
Industrial Hygiene Monthly Report Page 2
A
II. OSHA ASBESTOS STANDARD - continued
- CTEK, Inc. confirmed that they can perform asbestos-in-air analysis In compliance with the standard and provided the plant with a small quantity of asbestos sampling filters.
- Revision of the plant's asbestos handling program was begun.
III. COMPOUND VENTILATION
Collection hopper buildup was shown to seriously lessen total airflow through the building ventilation system. As a result, production began placing more emphasis on routinely checking and documenting:
- Collection hopper emptying - "Pulse Air" performance - Magnahelic gauge readings - Individual hood airflows, using the department's miniature velometer.
A variety of spot checks was made during the Line I modernization work to assist Engineering in obtaining an optimum air balance.
IV. LEAD/TOTAL PARTICULATES DOSIMETRY
Compound Line V workers were incorporated into the existing lead/total particulates dosimetry program.
V. SHORT-TERM EXPOSURES
Four, short-term VCM exposure measurements were made during the blanking of the 741 and 742 reactors. The measurements were made with REAL "Minimonitors" worn by three mechanics as they performed the work. A separate report summarizing these and previous results will be made.
Mechanic
A
B *
C *
D
Sample Time (Min.)
200
198
185
205
TWA Result (ppm, VCM)
0.1
0.2
1.0
1.4
* Mechanics C and D, besides helping blank out the tops and bottoms of the reactors, also, unlike Mechanics A and B, blanked out chemwash lines. The chemwash line to 742 had VCM trapped inside.
A series of short-term VCM exposure measurements during blend tank top opening was also begun. The measurements, also made with REAL "Minimonitors", were taken with the badges being worn by dryer operators as they opened blend tanks during reactor slurry dumping.
VAB.0001040143
Industrial Hygiene Monthly Report
Operator
Resin type
Blend Tanks
Sample Time (Min.)
TWA Result (ppm, VCM)
Wind Conditions
A
5305
646 & 647
3.0
14.2
S to N, 0-5 Hhi
B
5305
646 & 647
3.5
30.7
NW to SE, 0-5 MEH
C
5305
646 & 647
3.0
35.4
NE to SW, 0-5 MPH
A concurrent area survey was made in each case, using an HNU "Photoionizer". In all three cases, no detectable amount of VCM was found in the immediate, adjacent areas of the building roof. Reliable measurement near the blend tank manways was impossible because of high humidity conditions made worse by water vapor from the manways.
Additional samples are planned.
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c: JF, JWW, DWH, PJK, WFH, TFL, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwright, M.D. - Houston
VAB.0001040144
ABERDEEN CHEMICAL PLANT
i
ii ii
i----ii^--
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: June, 1986 Date of Report: July 28, 1986
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results
b
CHEMICAL
> PEL (OVEREXPOSURES) NO. %
VCM
80 97.6
Lead
15 93.7
Total Particulates
6 100.0
2 1
0
2.4 6.3
0.0
Overexposures
JOB CLASS Chief Operator
EXPOSURE
A 4k 2.9 ppm, VCM
SOURCE
Employee overexposed while preparing 742 reactor for a cooling jacket repair.
Instrument Technician
1.8 ppm, VCM
Employee overexposed calibrating the old fresh VCM receiver indicator.
while unit
level
Color Weigh Compounder
169.6 Micrograms Lead/M*3
Employee overexposed while weighing up small quantities
of Cyastab 988 and Trlbase EXL for Compound Line V in the Color Weigh Room. At writing, the source of the employee's recent overexpo sures has been investigated and related to work practice changes caused by Line V startup. Corrective measures are being taken.
* Respiratory protection was worn. ** Respiratory protection was not worn.
II. HAZARD COMMUNICATION PROGRAM
- A Hazard Communication Program makeup class was held for six people.
-- The Hazardous Material Reference Books were improved by adding index tabs and hi-lightlng the product names on all MSDSs.
VAB.0001040145
Industrial Hygiene Monthly Report Page 2
m. LAB VENTILATION
Lab ventilation hood airflows were checked. found.
No abnormalities were
IV. SHORT-TERM VCM EXPOSURES
Two short-term VCM exposure measurements were made during the blanking of the 745 reactor condenser. The measurements were made using REAL "Minimonitors1* worn by two mechanics as they performed the work. Conclusions about the need for respirator protection during this job are being deferred until additional samples have been taken.
Mechanic
A B
Sample Time
(Min.)
145 166
TWF Result (ppm, VCM)
^ 0.1 0.2
A
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c: JF, JWW, DWH, PJK, WFH, TFL, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwright, M.D. - Houston
%
VAB.0001040146
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: May, 1986 Date of Report: June 24, 1986
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
> PEL (OVEREXPOSURES) NO. %
VCM
82 98.8
Lead
18 94.7
Total Particulates
3 100.0
1 1 0
1.2
5.3
0.0
Ove rexposures
JOB CLASS General Mechanic
EXPOSURE
Ar 1.7 ppm, VCM
SOURCE
Employee overexposed while repairing VCM leaks at the VCM tank farm compressor shed.
Color Weigh Compounder
116.5 Micrograms Lead/M'*
Employee overexposed while weighing up Tribase XL, Trlbase EXL, and Cyastab 988 In the Color Weigh Room.
* Respiratory protection was worn.
II. HAZARD COMMUNICATION PROGRAM
Most of the month's Industrial hygiene activity Involved hazard communication. All compliance Items were completed before May 25th.
III. GILMONT PRECISION FLOWTUBE
The calibration of the Gllmont flowtube used with Bendlx air pumps during lead and total particulates dosimetry work was checked. No significant drift was seen.
IV. PLASTICIZER BUILDING VENTILATION
A study requested by Engineering was made of the air exchange rates Inside the Plasticizer building. Measurements were taken with a "hot wire" velometer, first with all windows and doors open, and then again with all of them closed.
A
VAB.0001040147
j
Industrial Hygiene Monthly Report Page 2
IV. PLASTICIZER BUILDING VENTILATION - Continued
The results, summarized below, showed that total air exchange in the reactor section of the building was roughly halved by closing all doors and windows, indicating a need for more makeup air during cold weather.
AIR EXCHANGES PER HOUR - PLASTICIZER BUILDING
Doors & Windows
Open
Closed
First Floor
42.4
21.2
Second Floor
32.0
16.2
rah
c: JF, JWW, DWH, PJK, WFH, TFL, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwright, M.D. - Houston
VAB.0001040148
A
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
I. ROUTINE CHEMICAL DOSIMETRY
Month: April, 1986 Date of Report: May 29, 1986
All Sample Results
CHEMICAL
PEL %
VCM Lead Total Particulates
77 100.0 17 100.0
8 100.0
II. OSHA VCM WORK PRACTICES CONTROL* *PLAN
> PEL (OVEREXPOSURES) NO. %
0 0.0 0 0.0 0 0.0
The plants OSHA VCM Work Practices Control Plan was reviewed. No changes were found to be needed. A letter stating the finding was written to file.
m. RESPIRATORY PROTECTION
The plantfs respirator program was revised and reviewed.
IV. HAZARD COMMUNICATION PROGRAM
Most of the month's Industrial hygiene activity Involved hazard communication. The status of the plant's compliance program is:
* Written Program - approved and distributed. * Training Program - classes complete, several make-up classes planned. * Signs - 95% complete.
* Chemical lists - complete - In Hazardous Material Reference Books. * Material Safety Data sheets - placed in Hazardous Materials Reference
Books - books distributed in plant.
* Chemical Inventory - Compliance audit conducted. Corrective measures 85% complete.
Safety Supervisor
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c: JF, JWW, DWH, PJK, WFH, TFL, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwright, M.D. -- Houston
VAB.0001040149
A
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: March* 1986 Date of Report: April 21, 1986
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
VCM Lead Total Particulates
Z. PEL
NO.
%
78 97.5
15 88.2
6 100.0
*> PEL (OVEREXPOSURES)
NO.
%
2 2.5
2 11.8 0 0.0
Overexposures
JOB CLASS Vinyl A Operator
EXPOSURE
& 1.5 ppm, VCM
SOURCE
Employee overexposed while performing his regular job duties in the old unit. The specific cause of his overexposure has not been determined.
Chief Operator
1.7 ppm, VCM Employee overexposed while performing his regular job duties. No specific cause for his overexposure has been determined.
Compounder
72.0 Micrograms Employee overexposed while
Lead/MJ
charging Line III blenders.
Color Weigh Compounder
46.1 Mic^ograms Lead /
Employee overexposed while weighing up Trlbase XL in the Color Weigh Room.
* Respiratory protection was worn. ** Respiratory protection was not worn.
RESPIRATORY PROTECTION
The plant's respirator program was reviewed, revised and re-submitted for approval.
VAB.0001040150
A
Industrial Hygiene Monthly Report Page 2
IV. HAZARD COMMUTATION PROGRAM The status of the plant's Hazard Communication Compliance program is: * Written Program - Submitted for final approval. * Training Program - Final preparations complete. * Warning Signs - All ordered, 40 percent installed. * Chemical Lists - Updated, ready to be placed in Hazardous Materials Reference Books. * Material Safety Data Sheets (MSDS) - Files of Hazardous and Non-Hazardous Chemical MSDS's have been copied and placed in Hazardous Materials Reference Books. The Hazardous Materials Reference Books will contain the plant's written program, Chem-List, and all Material Safety Data Sheets. The books will be distributed for easy employee access following Hazard Communication training in April.
Safety Supervisor /aeb c: JF, JWW, DWH, PJK, WFH, TFL, VEM, RAF, AHS, CWT
Tom Grumbles, J. R. Drumwright, M.D. - Houston
tm
VAB.0001040151
A
ABERDEEN CHEMICAL PLANT INDUSTRIAL HYGIENE MONTHLY REPORT
Month Of: February, 1986 Date of Report: March 25, 1986
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results Chemical
( PEL_______ No. %
VCM Lead Total Particulates
77 17
6
95.1 100.0 100.0
y PEL(Overexposures No. %
4 4.9 0 0.0 0 0.0
Overexposures
Job Class
Exposure
Source
Vinyl A Operator
1.6* ppi VCM
Employee overexposed while changing seal water filters in the old unit.
Chief Operator Vinyl A Operator
1.2* ppm, VCM 1.4** PP VCM
Employee overexposed while helping Vinyl A Operator (above) change filters.
Employee performed his regular job duties in the old unit. No specific cause for his overex posure has been determined.
Vinyl A Operator
1.2 ppm, VCM
Employee overexposed while locating VCM leaks in the old unit.
*Respiratory protection was worn. **Respiratory protection was not worn.
II. VENTILATION
Charts showing the acceptable ranges of airflows were posted on or near each Compound area ventilation hood. Operations then began dally airflow checks using their new, miniature velometer.
VAB.0001040152
Aberdeen Chemical Plant Industrial Hygiene Monthly Report Month of February, 1986
A
III. OSHA HAZARD COMMUNICATION STANDARD
The list of plant chemicals was updated using the newest MSDS's and then verified by the plant departments.
Signs and labels required for labeling were ordered.
The MSDS master file was reorganized to match the layout of the Hazardous Materials Reference Book.
An outline for use in conducting employee training was prepared.
Jerald V. Uptaln Safety Supervisor
/aeb
JWW, DWH, PJK, WFH, TFL, VEM, RAF, AHS, CWT Grumbles, J.R. Drurawright, M.D. - Houston
VAB.0001040153
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: January, 1986 Date of Report: February 20, 1986
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results CHEMICAL
< PEL
NO. %
> PEL (OVEREXPOSURES) NO. %
VCM Lead Total Particulates
83 98.8 14 82.4
6 100.0
1 3 0
1.2 17.6
0.0
Overexposures
JOB CLASS Chief Operator
EXPOSURE *
53.4 ppm, VCM
*
SOURCE
Employee overexposed while working next to a new unit filter pack change.
Color Weigh Compounder Compounder
134.7 Micrograms Lead/MJ
Ar 61.7 Micrograms
Lead/MJ
Employee overexposed while weighing up Cyastab 523, 564 and 988 in the color weigh room.
Employee overexposed while charging Line III blenders with Cyastab 564.
Compounder
36.6 Micrograms Lead/M'3
Employee overexposed while charging Line III blenders with Cyastab 564.
* Respiratory protection was worn.
II. VENTILATION
III.
The quarterly check of the compound ventilation system revealed decreased airflows through the Line III blender hoods. The hoods were then cleaned out by operations and re-checked, showing the flows to be back to acceptable levels.
RESPIRATORY PROTECTION
t
The plant's respirator program was revised and submitted for approval.
A
/
VAB.0001040154
Industrial Hygiene Monthly Report Page 2
IV. OSHA HAZARD COMMUNICATION STANDARD
The plant's hazard communication program was revised and distributed to plant department heads for comment.
Copies of Tel-A-Trains "Chemical Safety, Parts 1 and 2," videotapes were ordered for use in hazard communication training.
Rlngbinders for the plant's "Hazardous Materials Reference Books" were ordered.
V. SHORT-TERM VCM EXPOSURES
One set of short-term VCM exposure measurements was made during blanking of 744 reactor. The measurements were made, using REAL "Minimonitors" worn by three mechanics while they performed the work. As shown below. Mechanics "A" and "B" confined their work to blanking out the bottom of the reactor, while Mechanic "C" blanked out the condenser. Conclusions concerning the need for respiratory protection during this job are being deferred until additional samples have been taken.
Mechanic A B C
Sample Time
(Min.)
145
160
160
TWA Result (ppm, VCM)
< 0.1
< 0.1
5.1
Work Task Blanked out bottom of 744 reactor. Blanked out bottom of 744 reactor. Blanked out 744 reactor condenser.
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c: JF, JWW, DWH, PJK, WFH, CRS, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwrlght, M.D. - Houston
VAB.0001040155
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: December, 1985 Date of Report: January 16, 1986
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
>PEL (OVEREXPOSURES) NO. %
VCM
86 94.5
Lead
14 87.5
Total Particulates
7 100.0
5 2 0
5.5
12.5
0.0
Overexposures
JOB CLASS Yard Operator Instrument Technician
General Mechanic Dryer A Operator
EXPOSURE 3.0 ppm, VCM
Ar A 14.5 ppm, VCM
1.1 ppm, VCM
jfr A
1.5 ppm, VCM
SOURCE
Employee overexposed while hooking and unhooking VCM railcars.
Employee overexposed while helping replace the flush water valve above the new unit dump Sweco.
Employee overexposed while repairing the new unit slurry valve.
Employee performed his regular job duties. No specific cause for his overexposure has been f ound.
Vinyl A Operator
2.1 ppm, VCM
Employee overexposed while locating VCM leaks in the new unit.
Line I Compounder Line III Compounder
37.0 Mi5rograms Lead/
116.9 Micrograms
* Respiratory protection was worn. ** Respiratory protection was not worn.
Employee overexposed while cleaning Line I blenders.
Employee overexposed while charging the Line III blenders with Cystab 800.
A
VAB.0001040156
Industrial Hygiene Monthly Report Page 2
II. RESPIRATORY PROTECTION
Jerry Halford, of Respiratory Protection Services, Inc., conducted makeup, respirator face-fit testing of three employees.
Annual respirator training was completed.
III. VENTILATION
The fourth quarter check of the lab ventilation hoods was conducted. No abnormalities were found.
A
rah
c: JF, JWW, DWH, PJK, WFH, CRS, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwright, M.D. - Houston
VAB.0001040157
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: November, 1985 Date of Report: January 13, 1986
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
>PKL (OVEREXPOSURES) NO, %
VCM Lead Total Particulates
78 97.5 15 93.8
7 100.0
2 1 0
2.5
6.2 0.0
Overexposure s
JOB CLASS Vinyl A Operator
Vinyl A Operator
Compounder
EXPOSURE *
1.6 ppm, VCM
* 1.4 ppm, VCM
a
53.2 Mlcrograms Lead/n
SOURCE
Employee overexposed while investigating a leak in a new unit recovery line.
Employee overexposed while changing the old unit seal water filters.
Employee overexposed while weighing up compound in the Color Weigh Room on a temporary basis.
* Respiratory protection was worn.
H. OSHA HAZARD COMMUNICATION RULE
A list of the hazardous chemicals used In the Lab was compiled and added to the plant electronic data base.
The Hazard Communication Program was revised, following review of the first draft by plant department heads.
III. RESPIRATOR TRAINING
Annual respirator training was conducted.
IV. REACTOR MERCURY MANOMETERS
Traps were added to each of the ten vinyl reactor mercury manometers to contain mercury occasionally blown out of the manometer wells during process upsets.
A
VAB.0001040158
Industrial Hygiene Monthly Report Page 2
rah c: JF, JWW, DWH, PJK, WFH, CRS, VEM, RAF, AHS, CWT
Tom Grumbles, J. R. Drumwright, M.D. - Houston
4
A
VAB.0001040159
i
t
1
100
VCM
ABERDEEN CHEMICAL PLANT CHEMICAL DOSIMETRY TRENDS
Lead
0
100
Total Particulates
0
v
VAB.0001040160
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: October, 1985 Date of Report: November 25, 1985
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
PEL NO. %
VCM Lead Total Particulates
76 16
6
89.4 94.1 100.0
> PEL (OVEREXPOSURES) NO. %
9 10.6 1 5.9 0 0.0
Overexpo sure s
JOB CLASS Compounder
Yard Operator
EXPOSURE *
54.8 Micrograms Lead/n
* 1.3 ppm, VCM
SOURCE
Employee overexposed while charging Line III blenders with Tribase.
Employee overexposed while helping shift mechanic blank #4 VCM unloading station liquid line.
General Mechanic
General Helper Painter/Insulator/
Carpenter
Chief Operator
2.1 ppm, VCM 2.0 ppm, VCM
** 1.6 ppm, VCM
1.2* ppm, VCM
Employee overexposed while blanking #4 VCM unloading station liquid line.
Employee overexposed while pumping "pond" resin.
Employee overexposed while installing insulation covers above the old unit Sweco
Employee overexposed while preparing an old unit VCM return pump for mainte nance .
Vinyl A Operator Vinyl A Operator
68.5 ppm, VCM k
2.2 ppm, VCM
Employee overexposed while changing VCM filters in the new unit.
Employee overexposed while changing VCM filters In the old unit.
A
VAB.0001040161
Industrial Hygiene Monthly Report Page 2
Overexposures - continued
Job Class General Mechanic
Exposure 1.3 ppm, VCM
General Mechanic
67.1 ppm. VCM
* Respiratory protection was worn. ** Respiratory protection was not worn.
Source
Employee overexposed while replacing the chem wash and rinse valve on 741, 742 and 743 reactors.
Employee overexposed while opening the manway of the old unit south receiver in preparation for cleaning.
II. OSHA HAZARD COMMUNICATION RULE
The first draft of the plant's Hazard Communication Program was written and distributed to department heads for review. Included were depart ment lists of chemicals from the plant electronic data base.
III. GILMONT PRECISION FLOWTUBE
The calibration of the Gilmont precision flowtube used with Bendix air pumps during lead and total particulates dosimetry work was checked. No significant drift was seen.
IV. TOTAL PARTICULATES DOSIMETRY
All combination lead/total particulates dosimetry samples are now being sent to CTEK, Inc. for analysis of both items.
A
rah
JF, JWW, DWH, PJK, WFH, CRS, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwrlght, M.D - Houston
VAB.0001040162
'OO,
PEL
* " *
I
100
VCM
0
100
Lead
0
IOC
Total Particulates
0
ABERDEEN CHEMICAL PLANT
CHEMICAL DOSIMETRY TRENDS
1t i
i i i i II t f I s I i msi am
i 11 $ 11 s 1 i
VAB.0001040163
4
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: September, 1985 Date of Report: October 28, 1985
ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
>PEL (OVEREXPOSURES) NO. %
VCM Lead Total Particulates
68 17
5
94.4 100.0 100.0
4 0 0
5.6
0.0 0.0
Overexposures
JOB CLASS Vinyl A Operator Chief Operator Vinyl A Operator General Mechanic
EXPOSURE 11.2 ppm, VCM
2.8* ppm, VCM 3.6* ppm, VCM 4.8** ppm, VCM
SOURCE
Employee overexposed while locating the source of a VCM leak in the new unit.
Employee overexposed while locating the source of a VCM leak in the new unit.
Employee overexposed while locating the source of VCM leaks in the old unit.
Employee overexposed while removing insulation from a cooling water transmitter above the old unit dump Sweco.
* Respiratory protection was worn. ** Respiratory protection was not worn.
II. OSHA HAZARD COMMUNICATION RULE
The plant's plan for complying with the labeling requirements of the OSHA Hazard Communication Standard was finalized.
Data entry for the plant electronic data base was completed.
III. RESPIRATORY PROTECTION
A quarterly check of the plant respirator program was conducted. Several deficiencies were found and corrected.
A
i VAB.0001040164
Industrial Hygiene Monthly Report Page 2
IV. INDUSTRIAL HYGIENE PROGRAM ASSESSMENT
An assessment of the plant's Industrial hygiene program was conducted on September 24--25 by a team made up of T. Grumbles, M, Goodreau, K. Fogg, and J. Drumwright, M.D.
V. VENTILATION
The quarterly checks of the Lab and Compound ventilation systems were completed. One lab filter was found to be dirty and was subsequently cleaned. An across-the-board drop in airflow in the Compound "dry" system was found and corrected by emptying the building ventilation system collection hoppers.
A
rah
c: JF, JWW, DWH, PJK, WFH, CRS, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwright, M.D. - Houston
VAB.0001040165
mmmmm
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: August, 1985 Date of Report: Sept. 26, 1985
ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
PEL NO. %
>PEL (OVEREXPOSURES) NO. %
VCM Lead Total Particulates
63 16
5
91.3 94.1 100.0
6
1 0
8.7
5.9
0.0
Overexposures
JOB CLASS Color Weigh Compounder
Chief Operator
EXPOSURE A
66.2 Mlcrograms Lead/VT
Is 1.6 ppm, VCM
SOURCE
Employee overexposed while weighing small quantities of Tribase EXL and Dythal XL In the color weigh room.
Employee overexposed while preparing new unit east seal water subcooler for maintenance.
General Mechanic
ppm, VCM
Employee overexposed while blanking out, unheading, and cleaning the new unit seal water subcoolers.
Vinyl A Operator
1.2 ppm, VCM
Employee overexposed while repairing a pressure transmitter line on 742
Maintenance Supervisor Chief Operator
2.0 ppm, VCM 4.9 ppm, VCM
Employee worked In both vinyl reactor areas. The specific cause of his overexposure has not been determined.
Employee worked in both vinyl reactor areas. The specific cause of his overexposure has not been determined.
A
VAB.0001040166
Industrial Hygiene Monthly Report
Overexposures - Continued
Job Class Vinyl A Operator
Exposure 21.2 ppm, VCM
Respiratory protection was worn. ** Respiratory protection was not worn
Job Class
Employee overexposed while changing VCM filter pack filters in the new unit.
II. OSHA HAZARD COMMUNICATION RULE
MSDS receipt dates were added to the plant electronic data base.
The plant's plan for complying with the labeling requirements of OSHA Hazard Communication Rule was revised to Include suggestions made by T. G. Grumbles.
III. RESPIRATORY EQUIPMENT HANDLING
An audit of respiratory equipment handling, storage, and use was conducted. As a result, changes were made in Scott Air Pak storage case cleaning duties and the packaging of Scott Air Pak facepieces.
A
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JWW, DWH, PJK, WFH, CRS, VEM, RAF Grumbles. J. R. Dru:
CWT
VAB.0001040167
REVISED
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: July, 1985 Date of Report: Sept. 5, 1985
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
< PEL NO. %
> PEL (OVEREXPOSURES) NO. %
VCM Lead Total Particulates
80 16
9
98.8 94.1
100.1
1 1 0
1.2
5.9
0.0
Overexposures
JOB CLASS Vinyl A Operator
EXPOSURE
* 2.1 ppm, VCM
SOURCE
Employee overexposed while changing emissions recovery system filters.
Line III Compounder
54.9 Micro rams
Lead/
Employee overexposed while charging Line III blenders. No specific cause has been determined.
* Respiratory protection was worn.
II. NOISE CONTROL
The Noise Control Report and Plan recommendations were revised and the document re-submitted for review.
III. OSHA HAZARD COMMUNICATION RULE
The plant chemical electronic data base was set up and loaded, except for MSDS receipt dates.
Missing MSDSs were re-requested from the manufacturers.
The plant's plan for complying with the labeling requirements of the OSHA Hazard Communication Rule was reviewed with T. G. Grumbles. His suggestions are being incorporated into the plan.
A
Uptain
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JF, JWW, DWH, PJK, WFH, CRS, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwrlght, M.D - Houston
VAB.0001040168
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: July, 1985 Date of Report: August 19, 1985
I. ROUTINE CHEMICAL DOSIMETRY
Sample
CHEMICAL
PEL NO. %
> PEL (OVEREXPOSURES) NO. X
VCM Lead Total Particulates
80 16
9
98.8 94.1 100.1
1 1 0
1.2 5.9 0.0
Overexposures
JOB CLASS Vinyl Shift Supervisor
EXPOSURE 4.8 ppm, VCM
SOURCE
Employee overexposed while performing his normal job duties. No specific cause for his overexposure has been determined.
Line III Compounder
54.9 Microrams
Lead/
Employee overexposed while charging Line III blenders No specific cause has been determined.
Respiratory protection was worn. Respiratory protection was not worn.
II. NOISE CONTROL The Noise Control Report and Plan recommendations were revised and the document re-submitted for review.
III. OSHA HAZARD COMMUNICATION RULE The plant chemical electronic data base was set up and loaded, except for MSDS receipt dates. Missing MSDSs were re-requested from the manufacturers.
A
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MW*
VAB.0001040169
Industrial Hygiene Monthly Report Page 2
III. OSHA HAZARD COMMUNICATION RULE - continued
The plant's plan for complying with the labeling requirements of the OSHA Hazard Communication Rule was reviewed with T. G. Grumbles. His suggestions are being incorporated into the plan.
A
rah
c: JF, JWW, DWH, PJK, WFH, CRS, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwrlght, M.D. - Houston
VAB.0001040170
41 -`JHjw
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month Date of Report
June, 1985 July 24, 1985
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
^ PEL NO %
VCM Lead Total Particulates
79
15
6
97.5
100.0 100.0
> PEL------(-O----V---E---R---E---X---P---O---S---U----R- --ES) NO.
2 2.5
0 0.0 0 0.0
Overexposure s JOB CLASS
Vinyl "A" Operator
Vinyl "A" Operator
EXPOSURE 1.1
2.0
SOURCE
Employee overexposed while changing VCM filter pack filters In the old vinyl unit.
Employee overexposed while dumping a coarse batch in the old vinyl unit.
Respiratory protection was worn
II OSHAmm HAZARD COMMUNICATION RULE
Final revisions were made to the plant's plan for complying with the labeling requirements of the OSHA Hazard Communication Rule.
Preparations were made to begin the design and use of an electronic data base of all plant chemicals.
Ill VENTILATION MEASUREMENT
The quarterly ventilation checks in the Lab and Compound areas were done. Airflow through the Compound Line I mill hood was found below normal and subsequently corrected by adjusting the exhaust fan drive belts and cleaning out the ductwork.
A
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c: JF, JWW, DWH, PJK, WFH, CRS, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwright, M.D. - Houston
VAB.0001040171
A
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: May, 1985 Date of Report: July 2, 1985
ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
< PEL
> PEL (OVEREXPOSURES)
"So;
t~
VCM Lead Total Particulates
85 7 1
97.7
100.0
50.0
2
0 1
2.3
0.0
50.0
Overexposures
JOB CLASS
EXPOSURE
SOURCE
Maintenance Supervisor 1.4 ppm, VCM left
Vinyl Shift Supervisor 4.8 ppm, VCM
Employee worked in both new and old unit recovery areas, the top of the new unit chem wash tank, and at D400 con denser. The specific cause of the overexposure has not yet been determined.
Employee overexposed while training a new operator in the old vinyl unit. The specific cause of his over exposure has not yet been determined.
Line Ill/Dry Blend Utility
133.0 micrograms
Total Particulates /M3
\
* Respiratory protection was worn. Respiratory protection was not worn.
The employee was overexposed during a high dusting condi tion while he was cleaning out a plugged,Dry Blend master batch line. Although the sample result is being considered as an overex posure, it is thought to be elevated due to slugging of material into the inlet of the filter during the clean out work and not truly representative of airborne concentration.
VAB.0001040172
Industrial Hygiene Monthly Report Page 2
II. OSHA HAZARD COMMUNICATION RULE
The proposal for compliance with the labeling requirements of the OSHA Hazard Communication Rule was revised and re-distributed to department heads for further comment.
The plant's MSDS master file was revised.
A
Jerald V. Uptain
c: JF, JWW, DWH, PJK, WFH, CRS, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwright, M.D. - Houston
VAB.0001040173
t
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
ROUTINE CHEMICAL DOSIMETRY
Month: April, 1985 Date of Report: May 21, 1985
All Sample Results
CHEMICAL
VCM Lead Total Particulates
80 7 2
Overexpo sure s
94.4 100.0 100.0
PEL (OVEREXPOSURES) NO. %
5 5.6
0 0.0 0 0.0
JOB CLASS General Helper
EXPOSURE
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4t4t 1.8 ppm, VCM
General Helper
kk
1 1 ppm, VCM
General Mechanic Maint Supervisor
ppm, VCM 2.5 ppm, VCM
General Mechanic
kk
2.1 ppm, VCM
* Respiratory protection was worn. ** Respiratory protection was not worn.
SOURCE
Employee overexposed while covering a vinyl reactor area sewer found producing high VCM levels during firewatch duty.
Employee spent shift bagging PVC resin. The specific cause of his overexposure has not yet been determined.
Employee overexposed while blanking out D700 reactor.
Employee worked in all VCM areas. The specific cause of his overexposure has not yet been determined.
Employee worked in the main tenance shop and in the plasticizer tank farm while repairing a pump. The specific cause of his over exposure has not yet been determined.
VAB.0001040174
Industrial Hygiene Monthly Report Page 2
II. OSHA HAZARD COMMUNICATION RULE
A proposal for compliance with the labeling requirements of the OSHA Hazard Communication Rule vas prepared and given to department heads for review.
III. GILMONT PRECISION FLOWTUBE
The calibration of the Gllmont flowtube used with Bendlx air pumps during lead and total particulates dosimetry work was checked. No significant drift was seen.
IV. BLEND TANK TOP AREA VCM SAMPLES
Four blend tank top area VCM samples were taken using REAL "Minimonitor" badges to determine the need for respiratory protection in the vicinity of the tops of the small V-ll blend tanks during slurry trans fer from reactors.
The two samples taken on 4/15/85 were during the transfer of 5265 slurry from 745 reactor into the 650 and 651 blend tanks. Wind at the time was from north to south at 1-5 MPH. The temperature was 60F under cloudy
skies and during high humidity.
The samples taken on 4/16/85 were during the transfer of 5265 slurry from 745 reactor Into the 654 and 655 blend tanks. Wind at the time was from north to south at 1-2 MPH. The temperature was 66F under clear skies.
Sample duration was twenty minutes in all four cases.
The results clearly demonstrate that respiratory protection is needed in the vicinity of the small V--11 blend tanks during slurry transfer from the reactors:
Date 4/15/85
Sample Location
On top of 651 blend tank 4 inches south of hatch
Results, ppm VCM
<0.1
4/15/85
4 feet south and above 651 blend tank hatch
13.7
4/16/85
On top of 654 blend tank. 4 Inches south of hatch
19.7
4/16/85 ^
4 feet south and above 654 blend tank hatch
12.3
A
(/Jerald V. Uptain
c: JF, JWW, DWH, PJK, WFH, CRS, VEM, RAF, AHS, CWT Tom Grumbles, J. R. Drumwrlght, M.D. -- Houston
VAB.0001040175
0, 6
PEL
I
100
VCM
0
ABERDEEN CHB1ICAL PLANT CHEMICAL DOSIMETRY TRENDS
A
Lead
100 0
iJ
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i \__________ ___________._______________________ ___________
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______ ____________
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---------------- 1----------------
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1
IOC
Total Particulates
0
VAB.0001040176
mm
A
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
Month: March* 1985 Date of Report: April 25, 1985
I. ROUTINE CHEMICAL DOSIMETRY
All Sample Results
CHEMICAL
> PEL (OVEREXPOSURES) NO. X
VCM Lead Total Particulates
87 30
5
100.0 96.6
100.0
0 1 0
0.0
3.2
0.0
Overexposures
JOB CLASS Compound Line Operator
EXPOSURE
35.9 Micrograms Lead per M3
II. OSHA HAZARD COMMUNICATION RULE
SOURCE
Employee overexposed while operating Line I mill during a period of high dusting. Although a respirator is not usually required for this job, the employee was wear ing a disposal dust mask.
The in-plant hazard determination was completed and a list of the plant's hazardous materials sent to T. Grumbles, Houston, TX.
A list of missing or Inadequate material supplier material safety data sheets was compiled and preparations made for requesting new sheets.
Ill WEEKLY VCM DOSIMETRY REPORTING
The format of the weekly VCM dosimetry summary was simplified and the report re-implemented.
IV. VENTILATION MEASUREMENT
The quarterly ventilation checks in the Lab and Compound areas were done. No serious deficiencies were found.
Jerald V. Uptain
c: JF, JWW, DWH, PJK, WFH, CRS, RAF, AHS, WHM , JRW Tom Grumbles, J. R. Druanrright, M.D. - Houston
mmmm
mmmmmmmrnm
VAB.0001040177
i wf
ABERDEEN CHEMICAL PLANT
INDUSTRIAL HYGIENE MONTHLY REPORT
I. ROUTINE CHEMICAL DOSIMETRY
1
.1
1^----"f 111 IW 'll.
'
All Sample Results
.i
A
..J
CHEMICAL n # *
J,
VCM
*
Lead
*
Total Particulates
< PEL NO. %
86 97.7
6 100.0 0 0.0
Month: February, 1985 Date of Report: March 21, 1985
>PEL (OVEREXPOSURES) NO. X
2 2.3 0 0.0 0 0.0
Overexpo sure s
JOB CLASS Instrument Technician
EXPOSURE
A
5.0 ppm, VCM
SOURCE
Employee overexposed while removing the old unit VCM turbine meters.
General Mechanic
1.5 ppm, VCM
Employee overexposed while changing out a blown safety disc on 745 reactor.
* Respiratory protection was worn. ** Respiratory protection was not worn.
II. LEAD AND TOTAL PARTICULATES DOSIMETRY
Lead and total particulates dosimetry scheduling by job class was begun.
HI. VENTILATION MEASUREMENT
The Anemotherm model 60 Mhot--wire11 velometer was returned from factory
bis
JF, JWW, DWH, PJK, WFH, CRS, RAF, AHS, JRW Tom Grumbles, J. R. Drumwrlght, M.D. - Houston
VAB.0001040178