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DOW CHEMICAL U.S.A.
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CONFIDENTIAL
FOR THE USE OF DOW EMPLOYEES ONLY
INDUSTRIAL HYGIENE REPORT
EVALUATION OF POTENTIAL EMPLOYEE .V'OSUftES TO NOISE. ASBESTOS, AND CHLORINE/CAUSTIC - uliIT II, OYSTER
CREEK SITE
r.r^ 0CSII-2962HAC
c,.-t January < `.988
*-iho 0. R. Htthurln 2. . Jenkins
C,.S G**3tr.__
D. L. Alter: t f
ticcut0_Jii4aUa4. 3hjJbu-
C.A1L_______ ^ ^________________
P?',::nal exposures to noise, asbestos, and chlorine were ronitored during i86 and 1S87 a: dj-Caustic-Unit II, Oyster Creek Site. None of the average noise exposure levels exceeded the CSKA Standard for 8-hour and 12-hour work shifts, but did exceed 50% of OSHA allowable (action level) for Process Technicians and Sr. Process Technicians working 12-hour shifts and Repair Technicians working 8-hour shifts. A hearing conservation program is in -lace now with hearing protection being utilized. New recc-^endations for use of hearing protection are discussed in the body of this report. Results of an area survey conducted in June of 1986 arc also included in inis report.
Exposure to chlorine fi:d net exceed the Industrial Hygiene Guideline (;HS) of ! rpceiling for any of the personnel sampled. Additional chlorine iror.itonng i: planned for ; 9P.2.
t"D?9yee exposures to asbes`nt did not exceed the 0.2 f/cc OSHA limit. Asbestos exposure for one (1) contractor did exceed the OSHA action level of 0.1 f/cc. Asbestos will jo monitored again in 1988.
5T0085I82
'7
Z i*i
* 0<tro>J
0. E. Cragar. B-101 W. F. Cushman. H.D.. 6-101 G. V. Engdahl. 1803. Midland *J. t. LeBeau. !S03, Midland
Cover Sheet Only
*1. w. Ramoy. 1303. Midland N. G. Swank. 1803, Midland J. D. wade. CC-201 H. C. tfalcrcp, CC-201
AN OPI.HAfiNU UNIT QP TllF IX.MN OifMlClAt I lMIANY
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IKS File OCSII-2962NAC EVALUATION OF POTENTIAL EMPLOYEE EXPOSURES TO
Page 1
PURPOSE
'
.*.
Industrial hygiene monitoring was conducted at Cl? Caustic-Unit II Plant during
1586 and 1987 as outlined in t..e protocol. File *OCSJI-2962. Employee exposures to asbestos, noise and chlorine were evaluated. An area noise survey was also conducted and octave band analysis performed in problem areas. The -impose of this report is only to sumarlze the data since the measurements were collected by another industrial hygienist.
CONCLUSIONS
1. Process Technicians and Sr. Process Technicians working 12-hour shifts did exceed the action level (82 dBA). SC*. of the OSHA allowable (12-hour - 37 dBA). Repair Technicians working 8-hour shifts also exceeded the action level (8$ dBA). SOX of tne OSHA allowable (B-hour 90 dBA).
2. An area noise survey of the plant did determine some locations that exceeded the IIS dBA ceiling. An octave band analysis was conducted in several areas to help evaluate the -3:se source.
3. Chlorine exposures for Process Technicians in the chlorine comcrossion and cell areas were within the establisned Industrial Hygiene Guidelines.
A. Process Technicians and Sr. Process Technicians' exposures to asbestos were within the established Industrial Hygiene Guidelines.
5. One extractor uncovering cells during a chlorine cell senes assembly procedure was potentially exposed to an airborne concentration of .11 fibers per cubic centimeter asbestos. This level does exceed the action level of .10 fibers per cubic centimeter of asbestos, but uncovering cells is not a high occurrence activity.
RECOMMENDATIONS
1. The individual monitoring results have been communicated to employees. The results of this report must be communicated to e-iolo/ees and documented on the attached form. Training should be completed ar.d the form returned to Ind-Jdtrial Hygiene Services, 8*101. within 60 Cays of the date of this report (March 25. 1988).
2. Hearing protection rust be worn as outlined in the new Dow Texas Operations Safety Standard (0-5. 1918) whenever noise levels exceed 90 dBA (ceiling) or wnenever exposures exceed 85 dSA as a TWA. Areas with sound levels greater than 90 dBA shall be posted with signs to alert employees that heafmg protection is reouired in the area. Industrial Hygiene Services will assist the plant as necessary.3
3. Additional monitoring and evaluation of employee exposures to asbestos during chlorine cell maintenance operations shall be conducted.
IHS rile OCSII-2962NAC EVALUATION OF POTENTIAL EMPLOYEE EXPOSURES TO
Page 2
RESULTS AND OISCUS5ION
Personal TWA exposures and area surveys for noise were conducted in 1966-87 at
he Cl2 Caustic Unit II Plant. The sumary of average exposures and
Individual results are given in Table I and 11 respectively. The results of the area survey are listed in Table lit. Mean 8 and 12-hour TVA exposures for all job classifications were within acceptable limits. Process Technicians, Sr. Process Technicians and Repair Technicians Job classifications did exceed
the action level of 50* of OSHA allowable. Also three individual personnel
samples exceeded the IHG for noise and present a potential exposure only because hearing protection was being utilized. The area noise survey did designate some areas with greater than US aA. :ne area survey will establish a data base to designate areas greate** tr.an SO dSA in conjunction with Texas
Operations Safety Standard 0-46 newly is'.-td standards.
ST008518U
Table IV summarizes the asbestos and chlorine monitoring for 1985-27 at C12 Caustic - Ur it II. All personal TWA expires were less than the IHGs for asbestos. One of thirteen measurements v.*- a contractor pipefitter did exceed tne action level of .10 ftbers/cubic centimeter during the uncovering of a new chlorine cell prior to series assembly. The personal monitoring results for asbestos are listed in Table V and are oniy potential exposures because protective equipment and respirators are utilized.
On April 7 and 9, 1987, personal TWA exposures to chlorine were monitored for Process Technicians CHSE and Process Technicians Chlorine, for these samples, the Process Technicians CHSE is resoor.sible for operation of the chlorine compression and hydrogen recovery portion of the plant. The Chlorine Technician is responsible for the chlorine cooling and drying area. This includes collection and analysis of samples m this area. All individual TWA exposures to chlorine were less than the IHGs. The results of the chlorine monitoring are listed In Table VI.
EVALUATION CRITERIA
The Oow Industrial Hygiene Guide (OIHG). the American Conference of Governmental Industrial Hygienists (ACGIH) Threshold limit Value (TLV) ar.d the OSHA Permissible Exposure Limit (PEL) are the 8-hour time-weighted average (TWA) concentrations of airborne substances to which it is believed nearly all employees may be exposed throughout a working lifetime without adverse health effects. IHGs are intended to be used as guidelines for evaluating employee exposures and as aids for designing or modifying plants or operations- not as fine lines between safe and dangerous concentrations. Oow generated IHGs are developed by Occupational Health teams using toxicology information, industrial hygiene data and medical experience and are approved by the Oow Industrial
Health 2oard.
Host IHGs represent time-weighted average (TWA) concentrations for an 8-12 hour workday. 40-hour workweek. Limited short-term (excursion) exposures to higher concentrations are acceptable for most materials as long as the 8-hour TWA expose does not exceed the IHG. Excursion guidelines, in addition to the TUA
guideline, have been established for some materials which may cause adverse effects from brief exposures to relatively high concentrations. Professional judgment, rather than specific duration or frequency limits, should be used when applying these excursion guides. A few materials have IHGs which are ceiling exposures criteria, indicating that exposures should not exceed that level even for brief periods. IHGs are usually expressed in parts per million, volume by volume (ppm*v/v/) or milligrams of contaminant per cubic meter of air (mg/m3).
IMS File OCS11-2962IWC EVALUATION OF POTENTIAL EMPLOYEE EXPOSURES TO
Page 3
EVALUATION CRITERIA (Cont'd)
A "skin" notation nay used with an IHG to indicate that the material can be absorbed through the skin. For these materials, skin contact can contribute to the overall exposure; therefore, inhalation exposure evaluations nay not be
representative of total exposure.
Evaluation of noise exposure levels was based on the OSHA Pernissible Exposure Limit (PEL) of 90 C2A as an 8-hour TWA (1005). An exposure of 505 is equivalent to 85 dBA as .an 8-hour TWA. Employees with exposures greater than 50% of the OSHA allowable must be included in the Hearing Conservation Program.
Personal exposures are based on the following criteria;
ST0085I85
iasnl Asbestos
Chlorine Noise - 8-hour
12-hour
m .2 f/cc
--
90 dBA : 87 dBA
CtifUng -
1 ppm 115 dSA *90 dBA
Sayrce OSHA
OSHA OSHA DIHG
* Effective 11/9/87
SAMPLING AND ANALYSIS
Eight-hour measurements of asbestos were performed following the procedures outlined in the Occupational Safety and Health Asbestos Standard. Samples were collected using 25 mm mixed cellulose ester (MCE) fiber filters at a flow rate of 2.0 liter/minute and analyzed optically (MI OSH 7400).
Eight-hour measurements of chlorine during operation checks and collection of samples were conducted using the Hetrosonics chlorine monitoring systems as outlined in HEH-IHM-81-41. The Hetrosonics chlorine monitor and data
acquisition system employs an electrochemical sensor in which an aqueous electrolytic solution, exposed to ambient air via porous glass frit, generates an output current proportional to chlorine concentration in the air. The data is analyzed, printed out, and archived on an IBM computer via Metrosoft applications software.
Personnel noise dosimetry was done as outlined in Texas Operations hearing Conservation Manual using GenRad noise dosimeters. Area noise levels throughout the process area, lab. and the control room were measured with a GenRad (General Radio) Type 1988 Precision Sound Level Meter.
IMS File CCS 11 255?h'AC
TABLE 1 SUMMARY OF AVERAGE NOISE EXPOSURE
ST0085I86
Job dissipation
Job Number of % OSHA A]lovable Equivalent
Samples Ranqe
Averaoet
dBA
tzHatiL Shift
Process Tech - Electrical Sr. Technician-Electrical Sr. Technician-Instru-ent
22170E 25287E
3 i - 28
13 75
Process Tech-Cell Centro'. Sr. Tech-Oay Cell Control
22170PC 252870CL
Sr. Technician-Repair
Process Technician-Repair Unit Technician-Repair
25287P.
2217CR 25341R
Process Technician-Caustic 22170UA
Process Technician-Chlorine 221*00.
Sr. Technician-Chlorine
25287CL
Process Tcchnician-CKSE Sr. Tech.nician-CHSE
22170Cria 25287CHSE
3 16 - 42 7 12 107
S 2- 53 3 17 32 2 ie 20
30 ei iS 25
c 23 23 79 24 20
Process Technician-Utility Sr. Technician-Gas Turbine
Administrative & Clerical
22170UT 25287GT
...
12-Hour Shift
S 21 122
8 1 32 8-Hour IHG
Action Level
35
12.0 100
50
S3
75 90 8*
Process Techmsic-i-Caustic 22170KA
Process Technician-Chlorine 22170CL
Sr. Technician-Chlorine
252B7CL
Process Technician-CHSE Sr. Technician-CHSE
2217CCHSE 25257CH1E
3 20 6S 2 31 53
3 70 25
38 0 42 84
73 25
Process TechnicianTreating and Transfer
Process Technician-Utility Sr. Technician-Gas Turbine
22170TNT
22170UT 2S287GT
4 12 22 4 10 190
15 75 22 25
12 Hour IHG Action Level
100 50
87 82
i
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ilfS file CCS 11 - 2562UAC
I
TABLE II NOISE - PERSONAL MONITORING RESULTS
Job Classification
Master
Exposure
! Number HlS .. i (Win)
4
Process Tech-Caustic
206667 7-31-86
640
"1
202738 7-31-86
720
206667 8-01-86
710
j;
202445 7-01-86
470
$
202738 5-27-86
405
3
202433 5-25-85
405
L>
202588 7-03-86
435
<K* i
Contractor 7-02-85
445
*r> 'extractor instrument
and c!ec t r?ca 1
Contractor 7-IS-85 Contractor 7-14-65
475 455
Contractor 7-14-86
460
Process Technician '
`
Cell Control
261982 8-01-86
445
202751 7-22-86
580
205614 8-01-86
445
:j
"recess Technician
Chlorine l;
202705 202751 202308 202619
8-01-86 7-02-85 7-02-85 7-31-86
520 515 525 730
202735 . 7-31-86
630
f Process Technician
CHit
202345 7-31-85
650
i
202341 7-31-85
eeo
d *y
202345 3-01-85 202679 7-22-86
720 570
206254 7-03-86
410
T Proce-s Technician
Util ity 4 .. *
r v` ~
;< ^
202803 206254
202808 206254 202857 20525*4 202808
7-31-86 8-01-S5 8-01-35 7-31-86 7-09-85 5-27-86 6-25-S6
640 660 670 735 470 400 490
'!
202505 202857
7-22-86 7-01-86
280 450
;
Mk*
Time'Weighted Average % of OSHA Allowable
20 27 68
27 42 3] 24 52
't `
ST0085I87
28 8
32 42
16
19 17 32 53 31
K
85
64
70 30
b
18
69 190 60
53
122
21 61 34 93 t .
\^
l
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--- ....... ---....................... ..
----- 3
. -- -
IHS Hie OCSII -2S62NAC
TABLE II NOISE - PERSONAL MONITORING RESULTS
Job Classification
Master Number
Date
Process TechnicianTreating S Transfer
2C2254
2022C2 202SC7 2023:4
P-01-66 7-31-86 7-22-66 7-31-86
Traces* TechnicianReoa i r
202311 20225'. 206230
2022:I 206567 202251
8-01-e6
5-25-86
7-01-86 5-27-86 7-22-86 5-27-86
Ccr.tryctor Repair
Contractor 7-22-66
'pceis Engineer
N52-2 7-24-eS
Supervisor
202097 7-31-86
-rocess Engineer
201318 7-31-86
"echanical Supervisor
138669 7-31-66
process Engineer
230129 8-01-86
Process Special 1st
139853 8-01-86
process Engineer
2C2861 7-18-86
Exposure Time Mini...
650 715 480 620
425 420 46s 435 4i: 465
42:
44
495
470
475
480
480
470
Time-Weighted Average % of OSHA Allowable
15 12 22 13
12 68 </>
36 H
107 O 21 o
21 ao cn
80 --i
ao 12 ao
10
9
1
32
11
10
IMS file OCSI1-2962HAC
TABLE III AREA NOISE SURVEY AT CHLORINE/CAUSTIC - UNIT II
CRITICAL A^
,% Noise Level fdBAl
On driveway about 100 ft. from GT I
91
Air expelled from solenoid of Fi 410 B
90
Between P307 A & P307 B
92
3 ft east of P325 0
94
East side of GT II about 6* from HRU
93
G1 II Midway turbine (on deck)
93
Outside door of GT II enclosure door closed
102
about 4' fro* door
Inside enclosure at GT II Gas compressor coupling 118
^: On steps east of GT II Compressor coupling enclosure 102
GT I PSiG cabinet
55
a$ Hallway between FS40I S 0401 Platform of 6TI east side at AVC intake G1 I Midway on platform (turbine)
CAUSTIC AREA
92 100 96
3 ft. east of P325D
94
Between P)06 A A B
85
3 ft. south of P34S
89
3 ft. south of P322
87
2 ft. north of P330A; P330B.not operating
82
2 ft. east of P328B
66
/ 2 ft. north of P32BA South of P410 approximately 4 ft.
96 91
3 ft. north of P424A
79
4 ft. west of P40SA
85
3 ft. north of P401G
87
3 ft. north of P401F '>! 3 ft. north of PiOlE
87 e8
<4
jr
*1I
3 ft. south of P312 Between P33BA l P338B
34 90
Between P335A s P325B
e4
3 ft. east of T-68-1
51
Between P307A i P307B
92
li 2 ft. northeast of P32AA
68
J.i 3 ft east of T6S-2
, * 1 ft. north of P327
ea 71
2 ft. west of P102B pump (A)is not operating
85
2 ft. south of raw brineline also south of P316C
91
1 ft. west of Borg/Uarner hat. 60*42104
BO
northeast of trailer
- 2 ft. north of P336C 2 ft. north of P336B/P336A not operating
79 75
Between P414B l A
81
2 ft. west of P-3238
84
1 ft. south of P-351A
e6
2 ft. south of P-325A
65
2 ft. south of P-325B
91
ST0085189--
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IMS File OCSII-2962NAC
.'ABLE III AREA NOISE SURVEY AT CMlORJNE/CAUSTIC - UNIT M
CELL AW UTILITY AREAS
Noise Level
2 ft. south of P99A
91
2 ft. north of C202A
8
2 ft. west of C202B
91
3 ft. west of P2098: P209A not running
94
3 ft. north of P401A
91
3 ft. north of P401B
93
3 ft. north of P40IC
92
3 ft. north of P401D
92
North of CT401 sidestream filter
91
3 ft. north of CT401 control valve near
103
water tower
6 ft. southeast of PBU 402 level control valve 111
South of r5U 401 control box
10S
Between P421 AiB
92
South of P419 S P418 S P420
B8
P120 waste water recycle
91
2 ft. south of P120
92
East of GT II
91
Welding shop north
85
Gear oil compressor refrigerator unit (CO; tank) 84
Between P115A k P115B; between P210A k P210B
82
Between 260A and P260B
83
About 75' radius of sand blaster at work on top 84
of evaporation in Caustic
fdBAl
CAUSTIC.AND UTILITYAREAS Welding shop south Interior warehouse *1 Interior warehouse 3 About 75` radius of sand blaster at work cn top
of evaporator in tIAOH 10 ft. from Jack hammer operator General reading in building east of cells 4 ft. south of E401B 2 ft. north of P406 P309 not running west of pump Under pipeway at intersection of fire lane and
driveway in front of Utility 2 ft. east of 311A 2 ft. north of 3UB 2 ft. east of P328 3 ft. from P323B 2 ft. 329A Between P322 AiB
2 ft. southeast of P312A Directly at the bottom of the evaporator that
sand blaster is working on
81 e2 6^ 5a
101 75 93 95 78 ee 88 So 87 92 20 80 80 89 104
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IKS File 0CSII-296?r.vr
TAi.LE III AREA MOISE SURVEY AT CHLORINF/CA'JSTIC - UNIT II
CAUSTIC AMD UIILITY AREAS
Hoise Level fdBAl
CT <02 lower platforr. on top of red g-ating
65
General erea on top cf CT401
8<
D401 general area
101
Between C401 and FS401 wallwa/
94
Between D40S and P4095
97
UTILITIES AREA 5 ft. east or P<I<5
ICO ft. r.ortr of 0-205 r.iddle of walkway S ft. siuih of emergency generator under pipe*a/ 4 ft. west of filter-.te Bet-een C402 i E402 Between C402 i 0302 Between P402 AiB 3 ft. south of P402A 5 ft. west of P404 Between P4039 J P404 Between P403 AiB 3 ft. south of P417A
62
24 6? 52 79 88 91 50 90 91 91 90
2 CPlLCTJW-EI.l_Ajm 4 ft. south of A10S 4 ft. south of A104
Between c520 ALB Aux A/C rti
Air expelled froo solenoid i;f fl 4108 at 4' Between P602 A18 3 ft. west of T601 3 ft. north ofP6C3B South of PE01A 3 ft. south of P603A Between P201 AiB Between P212 AiB Between P260 AiB 2 ft. west of P251B
78 78
77
97 81 Bo 83
51
84 90 86 86 8S
BR1ME POND CELL AREA I UTILITIES 2 ft. west of P104A 2 ft. west of P107B 2 ft. west of P107C Surrounding area of P107 A.B.C north.
northwest, northeast Surrounding area of PI07 A.B.C south.
southwest, southeast 3 ft. south of P-411 On stairwell behind GT-ll Between P-405 AiB Between P-407 AiB 2 ft. south of GT-ll seal air tank 2 ft. west of P401 B: P401 A not running
90 52 87 91
92
90 97 92 98 102 96
MOTE: This area survey was conducted in June and July of 19B6 by Unit II personnel.
***:
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ST0085131
3
ST0085I92
o o o
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IHS ' tc OCSII-25'::nAC
TABLE IV SUW1ARY OF MONITORING OATA FOR ASBESTOS AMO CHLORINE
ASBCSIfli
Work Activity Collecting samples
Cell pulping
Job
Classification
Number of ilHlti..
Process Technician
17
B-Hour TUA In fibtrs/ci
Riaat
tetciM
0.01 0.03
0.02
Uncovering anc setting cells
Process Technician
13
0.02
Storing cells in warehouse
Process Technician
h
<c.ci - o.:i
<0.01
Removing astestos flange gaskets
Coverer
10
<0.01 0.01
<0.01
Removing spiral wound assestos
gasaets
Coverer
2 <0.01 0.02
0.02
Industrial Hygiene Guide
0.2 fibers/cc
Work Activitv
Chlorine CHiC
Job Classification
Number of Samples
Process Technician Process Technician
2
Industrial Hygiene Guide
PPH 8-Hr. TWA Excursion
.18 .39
. *^ a
l ppm C
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ST0085191
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TABLE VI
CHLORINE MONITORING RESULTS
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