Document MMqqmNbGe6xOr7j79kEOy605y
INTER-OFFICt MEMO TENNECO CHEMICALS, INC.
To G.I. Rozand
s
\rqm
Champion
At Piscataway AT Burlington
subject yQ^ Monitoring Compound Plant
Reference: (1) Memo, P. Gawason to W.C. Champion, "VCM Levels in Compound Air", No vember 19, 1974 (attached)
date November 26, 1974
A,copy to w. Britton H.B. Carr W.F. Gabel P. Gawason F.W. Kanzler F.X. Ritter P. R. Scarito
^Flle
(2) Memo, F.W. Kanzler to W.F. Gabel, "Compound Plant - Determination of VCM Levels in Compounds and Air", October 28, 1974
The attached memo by Paul Gawason details our findings in a detailed VCM exposure survey of the Compound Plant over a ten-day period (Oc tober 30th through November 11th). During this time, compounds representative of our entire product mix were run, so this survey should provide information typical of normal operations.
From the data presented, the following conclusions may be drawn:
1. Compound Plant operations can be brought below the OSHA exposure "action limit" of 0.5 ppm VCM by simple improvements in ventilation or changes in work practices.
2. Under current operating conditions, the action limit is reached oi' occasionally exceeded, even where low residual monomer content (<50 ppm) resin is used, in the following locations:
a. On the mixing platform, levels of 0.5 and 0.9 ppm were reached when resins containing 356 and 374 ppm VCM, respectively, were being blended. Lower residual monomer content resins would cor rect this.
b. On the CM feeder deck, even when low (18 ppm) residual monomer resin was used. Local exhausting with a flexible hose would eliminate this emission source.
c. At the CM outlet/pig conveyor, again even with low monomer con tent resin, extension of the mill or conveyor hood would correct this.
d. In the bagger area. Two incidents occurred (1.0 and 0.5 ppm with 18 and 374 ppm resin, respectively). Local exhaust in this area may be required.
COLORXTE 013220
3. No readings equaled or exceeded the action limit in the panel board, laboratory, warehouse or color room areas.
4. The general operating floor VCM 'background" was 0,1 - 0,3 ppm, as measured during runs where the dry blend being fed to the CM contained no detectable monomer.
5. Previous observations relative to VCM losses during compounding were confirmed: a. Principle monomer loss - 60% or more - occurs after plasti cizer addition in the dry blend state. b. Little or no monomer loss occurs during production of record compound. c. No monomer was found in the belt cooling water.
Attachment. WCC/jst
COLORITE 013221
TEHNECOINTER-OFFICE MEMO CHEMICALS, INC.
To W.C. Champion A
From P. Gawason
Subject VCM Levels in Compound Air and Various PVC Compounds Burlington Compound Plant
AT Burlington
AT Burlington _. ._
ATe. November 19, 1974
' CopYTO F Kanzler G.I. Rozand P*R. Scarito
^Pile
The attached table lists the amount of VCM present in various PVC com pounds and air samples in various work areas during the time period from 10/30/74 to 11/11/74. The data shows a x of 0,3 ppm VCM via pump air samples.
The compounds selected for testing were the large volume, flexible, un filled, filled,_semi-rigid and record compounds. Over this time period, approximately 2M_l8s of compound was produced with the samples tested representing 1.5M lbs of compound or about 75%. One complete set of sam ples were taken from each lot number with the exception of 2901-1 Natural01 where two complete sets of samples were taken per F.W. Kanzler's memo dated 10/28/74 (Compound Plant VCM Levels).
From this data, it is obvious that additional samples and test conditions axe required before 100% compliance to the 0SHA specification is attained.
Listed below are various parameters required to establish a detailed pro gram on VCM levels at the Compound Plant. These variables should be meas ured on each compound run, if possible:
1. the rpm of each blender should be checked to determine if this is con stant
2. recording of temperature of resin added to blenders
.3. recording of steam pressure on blenders
4 recording of plasticizer temperatures 5. recording of Quality Control Laboratory dry blend sample temperatures
.- -6. recording of dry blend drop-temperatures 7 recording of CM dry blend feed temperatures 8. recording of CM pig stock temperatures 9. recording of mill material temperatures 10. recording of pellet temperature in bags 11. recording of total cycle time in blenders 12. the effect of carbon black on record compound compared to a black, flex
ible compound.
Due to the various schedule changes at present, no additional'testing is pres ently planned.
Please advise future work or analysis required on future runs of PVC compounds.
Attachment. PG/jst
P. Gawason
COLORITE 013222
COLORITE 013223
I
Date
.ld/30/74
'^impound
2022 Gray 148
Lot Number
8-104317
1. Air Samples (PMP) a~. mixing platform; VCM, ppm
b. feeder deck; VCM, ppm c. between CM & panel bd; VCM, ppm d. pig conveyor; VCM, ppm e. mill area; VCM, ppm f. bagger area; VCM, ppm g. laboratory - mill area; VCM, ppm h. warehouse - storage area; VCM, ppm i. color room; VCM, ppm
0.2
0.2 0.2 0.2 0.1 0.1 0.1 0.1 0.2
2. Resin and Compound Samples
a~. resin as charged to blender; VCM, ppm
ND
b. "ctry blend - after raw mat1 Is added; VCM, ppm ND
c. dry blend - before drop; VCM, ppm
ND
d. belt feeder to CM; VCM, ppm
ND
e. CM pig; VCM, ppm
ND
f. mill slab; VCM, ppm
ND
g. pellets; VCM, ppm
ND
h. ribbon cooling water; VCM, ppm
ND
"vpe of Resin Used
250-12S
Lot Number
39402S
Time in Blender After Charge Compl.; minutes
55
Plastic izer a. type
Nuoplaz 6187
b. phr
59
c. phr of Camelwhite in resin sample d. type of stabilizer
basic lead silicate sulfate organic complex
10/31/74 2820 (2825) Natural
il/1/74 ^800 Natural
8-104318
8-104319
11/4/74 3086 Clear 22 8-114328
0.2 0.1 0.2 0.1 0.1 0.1 0.1 0.2 0.3
0.3 0.2 0.2 0.7 .0.6 1.0 ' 0.4 0.2 0.3 .
0,3 0.3 0.2 0.8 0.3 0.1 0.3 0.3 0.3
24 4 ND ND ND ND ND ND
Reposa
-
55
18 6.4 4,4 3.2 2.1 2.7 1.8 ND
Reposa
-
50
33 10 5.1 5,6 5.4 4.7 2.7 ND
Portugese
-
35
Nuoplaz 6908 DUP
28 22
10 tribasic lead sul fate organic complex
Nuoplaz 6908
53
15 basic lead silicate sulfate organic complex
Santicizer 790 Nuoplaz 849 Santicizer 711 38 4 O0
barium cadmium zinc complex
i.
11/5/74
J3j098 Clear
8-114329
0.5 6.7 0.2 0.1 0.3 0.1 ND 0.2 ND
356 65 34 26 : 11 13 13 ND
Flemington 225
ACFX 96313
30
Santicizer 690 Nuoplaz 849
20 5
monobutyl tin
COLORITE 0 1 3 2 2 4
inoii- 1 --
Date
Compound
Lot Number
1. Air Samples (PMP) a. mixing platform; VCM, ppm b. feeder deck; VCM, ppm c. between CM & panel bd; VCM, ppm d* pig conveyor; VCM, ppm e. mill area; VCM, ppm f. bagger area; VCM, ppm g* laboratory - mill area; VCM, ppm h. warehouse - storage area; VCM, ppm i. color room; VCM, ppm
Will'll
2901-1 Natural 01
8-114332
0.1 0.2 0.1 ND 0.2 0.1 ND 0.1 0.1
2. Resin and Compound Samples resin as charged to blender; VCM ppm
b. "dry blend - after raw mat'Is added} VCM, ppm c. dry blend - before drop; VCM,ppm d. belt feeder to CM; VCM, ppm e. CM pig; VCM, ppm f. mill slab; VCM, ppm g. pellets; VCM, ppm h. ribbon cooling water; VCM, ppm
'pc of Resin Used
#
Lot Number
Time in Blender After Charge Compl.; minutes
Plasticizer a. type
b. Phr
c. phr of Camelwhite in resin sample d. type of stabilizer
134 7.3 0.3 0.3 0.3 0.3 No NO
225/16R
234078
50
Nuoplaz 6908 T0TM
6.5 53.5 15 basic lead chloro silicate organic complex
j
11/8/74
2901-1 Natural 01
8-114332
0.8 0.2 0.2 0.2 0.4 0.5 0.1 ND 0.2
374 3.2 0.7 0.6 0.6 0.4 0.3 ND
F-9300
Bin 32
55
Nuoplaz 6908 TOTM 6,5 53.5 15 basic lead chloro silicate organic complex
11/8/74
2700 White
8-114331
0.1 0.1 0.1 0.3 0.1 0.1 0.1 0.2 0.2
11/11/74
3805-D Black
8-114339
0.1 0.1 0.3 0.9 0.1 0.1 0.1 0.1 ND
58 7.6 ND ND ND ND ND ND
'
Reposa
65
Nuoplaz 6055 Nuoplaz 6908 13.5 50 14
basic lead silicate sulfate organic com plex
218 190 180 184 211 218 229 ND
315
614043
55
_
tribasic leac dibasic lead
F. W. Kanzler 11/14/74
DRAFT SUMMARY QUALITY CONTROL MONITORING AND RECORD KEEPING PROCEDURES
Current
After January 1, 1975
After Computing System
A. Personal Monitoring
A. Personal Monitoring
A. Personal Monitoring
Using personal monitoring pump (Sipin-type), 45-50 ml/rain flow rate, charcoal absorption tube, monitor according to Procedure TAM 1-9:
Change from current as noted:
Change from January, 1975 as noted:
1. Target all polymerisation operating personnel, once per week, others once per month.
1. Target all polymerization operating personnel twice per month, others once per month.
1. Target all personnel once per month.
2. Actual 75% of personnel once per week (or month).
2. Actual 75% twice per month (on once-permonth).
2. Actual 75% once per month.
3. Sample at specific jobs, 10-15 minutes.
4. Analyze samples in accordance with Method GCF - 2.0.
*
5, Report:
5, Report:
a. Weekly exposure summaries by shift,. by person - to Works Manager, G. I. Rozand, W. C. Champion.
a. Bi-monthly exposure summaries by shift, by person - Works Manager, G.I. Rozand, W.C. Champion.
b. Weekly summaries by job classification to Works Manager, J.F. Kilcullen, G.I. Rozand, W. C. Champion,
b. Bi-monthly summaries by job classification to Works Manager, J.F. Kilcullen, G.I. Rozand, W.C. Champion.
c. Files maintained by Quality Control, Works Manager,
d
COLORXTE 0X3225
Page,2
iFT SUMMARY
QUALITY CONTROL MONITORING AND RECORD KEEPING
IDURES
1 Current
After January 1, 1975
d. Separate file for each person maintained by Works Manager.
6. Personnel whose monitoring samples exceed limit ( 50 ppm) advised verbally by foreman.
6. Advise personnel of exposures 1 ppm in writing.
B. OVA Area Monitoring
B. OVA Area Monitoring
Using Century OVA, monitor levels of VCM in air according to Procedure TAM 1-10:
Change from current as noted:
1. Monitor daily (5 days per week).
2. Report results to Works Manager, G.I. Rozand.
6. Separate report of reading exceeding stan dard (>50 ppm) to Works Manager, G.I. rozand, W,C. Champion. *
7. Files maintained by Works Manager,
6. Delete.
8. Monthly averages used to compute estim ated time-weighted exposure averages (TWA) for each job classification. Results re ported to Management; files maintained by Quality Control.
8. Delete.
C. Bendix Fixed Monitoring j Mot currently operable.
C. Bendix Fixed Monitoring Quality Control will operate, calibrate
After Computing System
***
!
7. Stored coded exposure information (by classi fication, by individual) on magnetic tape for later retrieval.
B. OVA Area Monitoring
Century OVA to be employed mainly for leak de tection in support of fixed monitoring system. Routine surveys of areas not covered by fixed system (outside areas) only.
C. Bendix Fixed Monitoring
" '
Change from January, 1975 as noted.
" s 1 !
C O L O R IT E
Page 3 -
SUMMARY - QUALITY CONTROL MOHITORIHG AND RECORD KEEPING PROj^ptES
Current
--
H U) IO fO
After January 1, 1975
After Computing System
and maintain the fixed monitoring system
in accordance with Procedure
:
i. All areas to be monitored continuously.
2. Calibration and operational checks once per day (7 days/week).
3. Tabulations of the readings for each point will be made once per day. Monthly averages will be used to estimate time-weighted exposure averages (TWA) for each job classification.
4. Results will be reported to Management in form suitable for posting. Files will be maintained by Works Manager.
5. Charts will be dated, signed and filed by Quality Control for 30 years.
6. Reporting and investigation of excur sions (>25 ppm) by Production personnel.
2. Calibration and operational checks daily by computer.
3. Tabulations of the range and average for each point will be computed once per shift. TWA's by job classification will be report ed once per shift.
4. Results reported daily.
5. Charts will be stored for one month.
7. Computer will print out all excursions over pre-selected limits on a continuous (real time) basis, for action and investigation by Production personnel.
8. Monthly report of area averages and TWA's will be prepared for Managerment.
9. All records will be stored on a monthly basis on magnetic tape, filed by Quality Control
W. C. Champio 11/26/74
C O L O R !T E