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ilFGoodrich INTER-ORGANIZATION CORRESPONDENCE TO R. J. Grahek FROM _______ _ ___^-glana Frlesz _______ SUBJECT Fiao POINT OR DCP1. & BLOG NO FIELD POINT OR DEPT & 81DG- NO. 1987 INDUSTRIAL HYGIENE St PLANT DATE YOUR LETTER DATE INIS LETTER 3/29/88 During 1987, Henry Plant personnel were monitored for exposure to noise, vinyl chloride, benzene, toluene, acetonitrile, formaldehyde, heavy meatals and dust (total PVC and total unspecified). The following exposure summaries reflect the results of this monitoring. I. NOISE (OSHA Permissible Exposure Limit = 100% dose/90 decibels) Ot3 Permissible Exposure Limit " 50% dose/85 decibels) DuPont Mark I noise dosimeters were used to spot check monitor 39 employees in different Job classifications for noise exposure. The noise dosimeter is worn by the employee to measure his total exposure to noise over the work shift. All continuous, intermittent and impulsive sound levels are integrated during the monitoring period to provide accumulative noise exposure in percent dose. Nineteen (49%) of the monitored employees exceeded the EFGoodrich exposure limit of 50% dose. Only nine (23%) exceeded the OSHA exposure limit of 100% dose. Hearing protection usage was 100% for all employees exceeding 50% noise dose who were working in posted areas. NOISE EXF06URB AVERAGE-BY BUILDING Building Polymer Chemicals (712) Wastewater Treatment Accelerator Building (725) Poly Building (731) Compounding Building (741) Dryer Building (732) No. of Personnel Monitored 13 3 4 8 4 6 Average Personnel Exposure 37.69% 38.52% 35.34% 81.30% 108.51% 109,61% II. COST (Total Dust Exposure Limit = 10 mg/m? Operators in the Compounding Building, Dryer Building, PC 712, Accelerator Expansion Building 725, and 3114 Building were monitored for total dust (unspecified or PVC). Most of these individuals were bagging finished product, but some of them were process operators. There were no individual dust exposures exceeding the specified limits. An MSA Flow-Lite sampling pump (set at 2 lpm flow) equipped with a PVC-5 filter inside of a three-piece cassette was used as the sampling device. BFG-495&-E MAO Pnnii'5 Cc n-y hi 0129-7 1 2- - TOTAL DOST EXF06URE Type Unspecified Unspecified Unspecified Unspecified FVC Siiiding Fblymar Chemicals/712 Compourxling/741 Accelerator Expansion/725 3114 Buildlng/722 Dryer Building/732 Ho. of Bersonnel Monitored 11 4 7 1 8 Average Bersonnel Ryprwiim 1.37 mg/W 1.60 ug/n? 0.63 mg/W 0.28 mg/m? 1.49 ng/W 111. BENZENE (HFG Permissible Exposure Lindt = 1 ppm) (06HA Permissible Exposure Limit = 1 pcm) Due to changes in the X-70 and Geltrol processes, the use of benzene was discontinued at the Henry Plant during the last quarter of 1987. However, monitoring for benzene exposure was done prior to this time and included a monthly representative operator on the X-70/Geltrol processes, and an annual representative from each other job classification where there was the potential for bezene exposure. Representative operators at the Wastewater Treatment plant and the Laboratory were also monitored. There were two benzene exposures at 1 ppm, but none that exceeded this level. 1987 EENZBTC EXPOSURE AVERAGE (PPM) BY BUILDING RHlding Polymer Chemicals (712) PI Maintenance (713) Wastewater Treatment (721) Laboratory (718) No. of Personnel Mnnitonftd 24 2 4 1 Average Personnel Exposure 0.24 ppm 0.20 ppm 0.10 ppm 0.20 ppm IV. TOLUENE (Permissible Exposure Limit = 100 ppm) Toluene was substituted for benzene in the X-70 and Geltrol processes at the end of October. Due to this change, monitoring for toluene was started in the Fblymer Chemicals building 712 to determine if there was an exposure problem. The monitoring results indicate that toluene exposure is very low. Spot-check monitoring will be done on a monthly basis for a representative operator on the X-70/Geltrol process, and monthly for a representative operator from each other job classification which may be subject to Toluene exposure. kcpjj&si No. of People Monitored____ 18 Average personnel Exposure 0.24 ppm Maximum 1.0 ppm NGC 01298 -3- V. ACETONITRILE (Berraissible Exposure Limit = 40 ppm) For 1987, the acetonitrile exposure average in the 3114 building (722) was 14.2 ppa. A quarterly spot-check monitorir is done of a representative operator in the area. Only one sample taken during 1967 exceeded the permissible limit. An operator received an exposure of 51.7 ppm on a day when the building sewers were being steamed out. This unusual activity, which will now be listed as a "respirator-required" task, apparently caused higher Acetonitrile levels In the building. The nwvlmim exposure from other personnel monitorings for Acetonitrile exposure was 2.1 ppm. VI. METHYLENE CHLORIDE (Permissible Exposure Lindt = 100 Fin) A quarterly spot-check sample is also done In the Accelerator Expansion Building for Methylene Chloride exposure. The 1987 monitoring results show the average exposure to operators in the 725 building to be 1.4 ppm. Monitoring will continue at the spot-check frequency unless problems occur. VII. HEAVY METALS (Permissible Exposure Limits: Antimony =0.5 mg/n Cadmium = 0.5 mg/hP Chromiimi = (Haxavalent = 0.05 mg/to?) (Trivalent = 0.5 mg/b?) Nickel = 1 mg/b? The operators in compounding who weigh up pigments and empty the mix into the henschel are monitored periodically for heavy metal exposure. The 1987 monitorings continued to show that there is no exposure problem in this area. HEAVY METAL EXPOSURES IN .M.5lSCl;5U. Heavy total No. of People Average Personnel Rvpnmnr^ Antimony fiadmhm Chromium Nickel 6 0.005 mgA? 6 <0.001 mgyhj3 6 0.007 mg/bP 4 <0.001 mg/bP NGC 01299 -4- VIII. VINYL CHLORITE (Ftertnissible Exposure Limit = 1 ppm) All operators in the roly and Dryer Building as well as the FVC Tank Farm are monitored for vinyl chloride exposure at least onoe per year. The schedule of monitoring then follows the OSHA VC1 standard which requires monthly monitoring for any exposure greater than 0.5 ppm until two consecutive monitorings are less than 0.5 ppm. The employee need not be monitored again during the year if his annual monitoring result or the two consecutive monitorings are below 0.5 ppm. All VC1 monitoring samples were collected on Reiszner gas badges. The 1987 VC1 personnel monitoring results are summarised below: VINYL CffiflRIEE MONITORING (POLY AND DRYER BUILDING') Year No. of People Monitored Average (van) % Greater % Less Than 0. 5 van 1985 1986 1987 231 315 248 1.58 1.79 1.06 38 40 21 34 30 58 RESPIRATOR COMPLIANCE fFQLY BQILDIMB1 Year No. of Exposures No. of Exposures Greater than 1 W/O Respirator Respirator Coral lanra 1985 1986 1987 87 131 33 62% 49 63% 15 72% Of the exposures greather than 1 ppm without respirator protection, seven each were from LoSope charge and Recovery job classifications. No other explanations for the exposures were given. The remain!r exposure was to a Pearl Charge Operator. There were also four exposures in the Dryer ftdldlng during 1987 that were greater than 1 ppm. Respirators were not worn during these exposures. Operator Heredia Date 3/31 Exposure 1.7 ppm Explanation Ran Resin Reclaim on 178 B, changed out transfer pump in Poly Building. Keegan 3/31 1.0 ppm Bagged 178 B from Resin Reclaim for two hours. Heredia 4/1 1.3 ppm Ran Resin Reclaim on 178 B. Jason 8/12 1.4 ppm Dryer operator (Resin Reclaim ran 178 B on this date) NGC 01300 -5- Even with -the above exposures included, the Dryer Building exposure average for 1987 was less than the action level (0.5 ppn). VINYL CHLORIDE KXFOBOKB BY JOB CLASSIFICATION .inh niuM No. of People Monitored Average (pan) Helper/HRC Roly Cleaner bVC Tank Farm Operator Recovery Operator ffeste/LoSope Charge Operator Raarl Charge Operator FVC Foreman Efcyer Operator Efcyer Building Bagger Valve Cleaner Catalyst Make-up Dryer Building Foreman SAR Operator Wastewater Treatment Operator 27 2 27 34 44 16 37 24 8 2 9 3 8 2.59 2.41 1.56 1.50 1.19 0.69 0.34 0.30 0.28 0.20 0.19 0.13 0.13 * The wastewater treatment operators have been spot check monitored for vinyl chloride exposure because of several area monitoring that were above 1 ppm in the sludge dewatering building. However, it seems that the wastewater treatment operator does not spend enough time in the sludge dewatering building for his exposure to become significant. DC CONCLUSION Overall, there are no serious industrial hygiene problems in most areas of the Plant. In fact, with the removal of benzene from the Polymer Chemicals building, the tasks that previously required respirator usage for benzene exposure now do not require any protection for toluene. There is, however, still an occasional vinyl chloride exposure in the Dryer Building that exceeds 1 ppco. And since this area is not regulated for VC1 exposure, no respiratory protection is worn. Although the exposure levels fluctuate and there are many very low exposures betreen pop-outs, there does seem to be a correlation between the higher exposure and "B" grade (Blend Tank 5) material running in Resin Reclaim. Additional ventilation is being considered around the second floor press area of the Resin Reclaim building in order to lower VC1 emissions. OVA readings in this area during press dropping and water flushing have shown increased VC1 levels. rxkn/E124 VjoOJivO^ Diana Friesz NGC 01301 Distribution: M. E. Guyer D. E. Giffin D. L. Rys J.P. Griffin J. A- Bernard! K. J. Hillings R. C. Linneman V.D. Marquis F. V. Zemanek R. D. Webber S&E Operators (2) T.S. Rialto - Cleveland C. K Andersen - Cleveland File v {^Goodrich INTER-ORGANIZATION CORRESPONDENCE TO M. E. Guyer FPOM Diana Frlesz__________ SUBJECT FIELD POINT OR DEPT 4 BLDG NO FIELD POINT OR DEPT & BLDG NO. INDUSTRIAL HYGIENE UPDATE FOR THE THIRD QUARTER OF 1987 DATE YOUR LETTER DATE THIS LETTER 11/13/87 Henry Plant personnel monitoring results for the third quarter of 1987 are summarized as follows: I. NOISE (BFG Permissible Exposure = 50% Dose) Building No. of Personnel Monitored Average Personnel Exposure Dryer Building Compound Building 6 4 110% 108% Both of these work areas are posted as "High Noise" areas. Compliance with hearing protection requirements was 100% for the monitored employees. II. (Permissible Exposure Limit 10 rag/ra3) Building No. of Personnel Monitored Average Personnel Exposure Compound Building Polymer Chemicals (712) Accelerator Building (725) 2 3 3 1.46 mg/m3 1.00 mg/m3 0.68 mg/m3 III. HEAVY METALS (Permissible Exposure Limits: Antimony = 0.5 rag/ra3 Cadraiura - 0. 05 rag/ra3 Chromium = (Hexavalent - 0.05 rag/ra3) (Trivalent - 0.5 mg/m3) Nickel 1 rag/ra3 Periodic spot-check monitoring is done to determine Compounding Operator exposure to heavy metals. The results continue to show there is no heavy metal exposure problem during pigment weighing and/or emptying pigment to the henschel. No. of Personnel Monitored Average Personnel Exposure Antimony Cadmium Chromium Nickel 3 < 0. 001 rag/m3 3 <0. 001 rag/m3 3 < 0.001 rag/m3 3 0.000 ms/m3 BKj- 4956-C s r> *' *>' i i . NGC 01303 -2 IV. BENZENE (Permissible Exposure Limit = 1 ppm, 0.5 ppm Action Level) Building No. of Personnel Monitored Average Polymer Chemicals (712) Maintenance (Polymer Chemicals) 7 1 0.28 ppm 0.20 ppm Of the benzene samples taken in Building 712, one was at the action level and one was at the permissible exposure limit. Both exposures occurred to operators performing non-routine jobs while wearing respirator protection. V. ACETONITRILE (Permissible Exposure Limit = 40 ppm) A quarterly spot check was done in the 3114 building for Acetonitrile exposure. The result (1.80 ppm) continues to show that there is no exposure problem in this area. VI. VINYL CHLORIDE (Permissible Exposure Limit = 1 ppm) No. of Personnel Monitored Average Personnel Exposure Poly Building Dryer Building 22 21 0.76 ppm 0.37 ppm There were 43 VC1 personnel monitoring samples taken in the Poly and Dryer Buildings during the third quarter of 1987. Of these, six samples (13.9%) exceeded one ppm. Twenty-nine (67%) of the total VC1 samples were below the 0.5 ppm action level. Three of the samples that were greater than one ppm occurred without the use of respirator protection. Respirator compliance for this period was 93%. rdm/E80 cc: R.J. K.J. T.S. J.A. F.V. V.D. R.C, J.P. M. A. C.K R. D. D.E. D. L. Grahek Killings Bialke (Cleveland) Bernard! Zemanek Marquis Linneman Griffin Ackerman Andersen (Cleveland) Webber Giffin Rys Diana Friesz NG< 01304 TO M,E. Guyer FROM Diana Friesz SUBJECT FIELD POINT OR DEPT 4 61DG NO FIELD POINT OR DEFT 4 61DG NO INDUSTRIAL HYGIENE UPDATE FOR THE SECOND QUARTER OF 1987 DATE YOUR LETTER DATE THIS LETTER 7/29/87 Henry Plant personnel monitoring results for the second quarter of 1987 are summarized as follows: I. NOISE (BFG permissible exposure = 50% dose) Building No. of Personnel Monitored Average Personnel Exposure Poly Building Polymer Chemicals (712) Accelerator Building 8 6 1 81.30% 31.36% 28.20% II. DUST/TOTAL (Permissible exposure limit = 10 rag/m3) Building No. of Personnel Monitored Average Personnel Exposure Compounding Polymer Chemicals (712) Accelerator Building 3114/3125 Building 2 1 3 1 1.75 1. 55 0. 45 0.28 mg/no3 mg/m3 mg/m3 mg/m3 Two of these samples were sent to the Brecksville Laboratory for determination of the Cure-Rite 18 content of the total dust sample. The amounts of Cure-Rite 18 detected were 0.012 rag/m3 and 0.006 rag/ro3. The current BFGoodrich established exposure limit for Cure-Rite 18 dust is 0. 1 rag/m3 . III. BENZENE (BFG Permissible exposure limit - 1 ppm; OSHA exposure limit- 10 ppm) Building No. of Personnel Monitored Average Maintenance Polymer Chemicals (7 12) 1 9 0.2 ppra 0. 18 ppra Only one Benzene exposure during the second quarter was above the action level of 0.5 ppm. There were no exposures exceeding 1 ppm. INGC 01305 2- - IV. VINrL CHLORIDE (Permissible exposure limit = 1 ppm) Building No. of Personnel Monitored Average Personnel EXPOSUXQ Poly Building Dryer Building 39 18 1.21 ppm 0.34 ppm There were 57 VCL personnel monitoring samples taken in the Poly and Dryer Buildings during the second quarter of 1987. Of these, 13 samples (22.8%) exceeded one ppm. Thirty-seven (65%) of the total VC1 samples were below the 0.5 ppm action level. Four of the samples that were greater than one ppm occurred without the use of respirator protection. Respirator compliance for this period was 93%. V. ACETONITRILE (Permissible exposure limit = 40 ppm) A quarterly spot check of the 3114 process was done for Acetonitrile exposure. The result (2.1 ppm) continues to demonstrate that there is no Acetonitrile exposure problem in this area. VI. METHYLENE CHLORIDE (Permissible exposure limit 50 ppm) Area samples for Methylene Chloride have shown very low exposure in the Accelerator Expansion Building while the Cure-Rite 18 process is running. A MeCl2 personnel monitoring sample taken during second quarter was analyzed at 0.6 ppm. VII. ASBESTOS (Permissible exposure limit =0.2 fibers/cc; Action level =0.1 fibers/cc). Personnel monitoring for asbestos fiber exposure is being done for each asbestos removal job performed by Cardinal Insulation and for our Plant Audit team while sampling insulation. An. open-face, extended cowl cassette with a 25 mm, 0.8 um mixed cellulose ester filter is used for this monitoring. The pump flow rate is set at 3 Lpm. To date, asbestos fiber exposure for both groups have been well within the accepted limits. Out of 45 monitorings the asbestos fiber exposure average for Cardinal during abatement work was 0.02 fibers/cc. All exposures for the Plant employees auditing asbestos-insulated pipes/equipment were below the limit of detection (0.01 fibers/cc). NGC 01306 -3- VIII. NEW PROJECTS 1. Sample for manufacturing. Morpholine exposure during Cure-Rite 18 2. Perforin area and personnel monitoring for toluene exposure during X-70/Geltrol conversion and revise PC Environmental Floor Procedure. 3. Monitor PC bagger for MBTS exposure per Toro Bialke's request. rdro/E68 cc: R.J. Grahek K.J. Hillings T.S. Bialke (Cleveland) J.A. Bernardi F. V. Zeroanek V. D. Marquis R.C. Linneroan J.P. Griffin M. A. Ackerman G. Kr,--Anderson CClevelaiid) R. D. Webber D.E. Giffin D. L. Rys N. L. Kuchenroeister u Boc-sc^f K A1AAT! /O Diana Friesz Cl K OiMxisiAAwru jjO APrtfL (<\S> HlS ^ ms NGC 01307 ilFGoodrich INTER-ORGANIZATION CORRESPONDENCE TO M.E. FROM D.G. SUBJECT Guyer Friesz FIELD POINT OR DEPT & BLDG NO FIELD F>OlNT OR DEPT fc BLDG NO INDUSTRIAL HYGIENE UPDATE FOR THE FIRST QUARTER OF 1987 DATE YOUR LETTER DATE TWIS LETTER 5/19/87 Henry Plant personnel monitoring results for the first three months of 1987 are summarized as follows: I. NOISE (BFG permissible exposure = 60% dose) Building No. of Personnel Average Personnel Exposure Polymer Chemicals (712) Wastewater Treatment Accelerator Bldg. (725) 1 3 1 69.60% * 38.52% 23.04% * Geltrol process alarms going off during work period. Noise levels on the first floor of Polymer Chemicals (712) have been reduced due to the installation of a noise barrier curtain around the OBTS bagger blower. The OBTS operator standing at the bagger nozzle is now exposed to 83 decibels as compared to 88 - 90 decibels before the curtain was in place. II. DUST/TOTAL (Permissible exposure Limit = 10 mg/m3) No. of Personnel Monitored Polymer Chemicals (712) Accelerator Bldg. (725) 2 1 Average 2.69 mg/m3 1. 08 mg/m3 III. BENZENE (BFG Permissible Exposure Limit = 1 ppm, OSHA Exposure Limit = 10 ppm) Bu11d1nw No. of Personnel Monl t.ored Average Personnel Exposure Wastewater Treatment Laboratory Maintenance Polymer Chemicals (712) 3 1 1 7 0.13 ppm 0.20 ppm 0.20 ppm 0. 27 ppm IV. HEAVY METALS (Permissible Exposure Limits: Antimony - 0.5 mg/m3 Cadmium - 0,05 rag/ra3 Chromium (Hexavalent - 0.05 rag/ro3), (Trivalent - 0.5 rog/m3 ) Nickel - 1 mg/m3 B F- G-49SH- F RnTTiTVTNG Compounding Dryer Building Poly Building A/E Building 3114 Building PC Building 712 Boiler House (719) MBT-C/NaMBT HENRY PLANT NOISE EXPOSURE HISTORY NO. EMPLOYEES 19B7 PERCENT EXPOSURE AVERAGE BY YEAR 1986 1985 1984 1983 36 108.5% 58.6% 133.5% 91.8% 79.3% 57 109.6% 67.6% -- 70.2% 47. 15% 101 81.3% 51.4% 50.1% 56.9% 61. 1% 8 35.3% 49.3% -- ---- 21 52.6% 48.1% 41.0% 24.9% 29.4% 196 37.7% 39.9% 29.1% 24.9% 25.3% 21 -- 24.8% 36.3% 42.2% 38.3% 23 -- 21.9% -- 19.9% 11.2% Noise Regulated Areas 50% Dose = EFG Exposure Limit for Noise 100% Dose = OSHA Exposure Limit for Noise VINYL CHLORIDE PERSONNEL MONITORING POLY AND DRYER BUILDINGS YEAR 1988 1987 1986 1985 1984 NO. OF SAMPLES TAKEN 146 261 315 229 168 NO. > i mi 27 (44%) 57 (21.8%) 131 (41.5%) 87 (38%) 32 (19%) NO. < 0-5 PPM NO. >1 i 69 (47%) 15* 153 (58.6%) 19 95 (30%) 49 79 (34.5%) 35 96 (57%) 15 RESP. COMPLIANCE 44% 67% 63% 60% 53% *FOCR OF THESE EXPOSURES OCCURRED IN DRYER BUILDING NGC TO: P. Donataccio FROM: D. G. Friesz 3/17/89 1988 INDUSTRIAL HYGIENE SUMMARY-HENRY PLANT During 1988, Henry Plant personnel Mere nmitorod for exposure to noise, vinyl chloride, toluene, acetonitrile, formaldehyde, heavy metals, dust (total PYC and total unspecified, and silica . The following exposure summaries reflect the results of this ranitorlng. I. Noise (06HA Permissible Exposure Limit 100% dose/90 decibels) (EFG Permissible Exposure Limit 50% dose/85 decibels) DuPont Mark I noise dosimeters were used to monitor 82 employees in different job classifications for noise exposure. The noise dosimeter is worn by the employee to measure his total exposure to noise over the work shift. All continuous, intermittent and impulsive sound levels are Integrated during the monitoring period to provide the accumulative noise exposure in percent dose. Fifty-two (63%) of the monitored employees exceeded the HEGoodrich exposure limit of 50% dose. Only fourteen (17%) exceeded the OSHA exposure limit of 100% dose. ARPA JOR fTT-ASS NOISE EXPOSURE BY AREA NO. OF EXPOSURE MONITORINGS AVERAGES NO. >50% DOSE WITHOUT HEARING PROTECTION HEARING PROTECTION COMPLIANCE FOR AREA Roly Bldg HKC Pbly Cleaner Blending Resin Operator Poly Bldg Foreman Pearl Charge Operator Paste/LoSope Operator Valve Cleaner Recovery Operator 4 1 4 12 8 2 7 100.98 68.40 60.42 55.06 54.14 47.85 44.79 1 0 1 1 0 0 0 86% Dryer Bldg Dryer Operator PVC Bagger Dryer Foreman Silo Operator 10 114.58 0 2 110.40 1 4 31.41 0 2 30.78 0 91% Compound Bldg Relief Operator Mill Operator Henschel Operator ComP- Packager Silo Operator 3 115.24 0 5 102.05 0 3 82.24 0 3 34.92 0 2 30.78 0 100% NGg 0131 NOISE EXPOSURE BY AREA (Continued) AREA JOB CTASA NO. OF MnNTTORTNGS EXPOSURE AVERAGE f%) NO. >50% DOSE WITHOUT HEARING PROTECTION HEARING PROTECTION COMPLIANCE FOR AREA Utilities Coal Boiler Operator Gas Boiler Operator 2 2 54.64 54.40 0 0 100% Polymer Chemicals (712) PC Bagger OBTS Operator St&lite/VanLube Operator 1 3 1 62.60 48.52 19.08 *Indicates areas that are currently posted as 'High Noise*4 and hearing protection required. Only the mill and henschel areas are affected in Confounding. II. COST (Total Dust Exposure Limit = 10 mg/W Operators in the Confounding Building, Dryer Building, PC 712, Accelerator Expansion Building 725, and 3114 Building were monitored for total dust (unspecified or PVC). Most of these individuals were bagging finished product, but some of them were process operators. There were no individual dust exposures exceeding the specified limits. An HJA Flow-Lite sampling punp (set at 2 1pm flow) equipped with a PVC-5 filter inside of a three-piece cassette was used as the sampling device. TOTAL DUST EXPOSURES Typa Jr>h Class No. of Average Personnel Monitored Exposure PVC PVC Unspecified PVC Unspecified Unspecified Unspecified Dryer Operator (732) PVC Bagger (732) Henschel Operator (741) Contract Employees (732) PC Bagger (712,722,725) Mill Operator (741) OBTS Operator (712) 4 3 2 2 1 2 2 1.08 wg/nP 0.74 mg/m5 0.69 mg/mi5 0.57 rog/ro5 0.46 ng/nP 0.38 rag/mP 0.24 rog/m5 III. CRYSTALLINE FREE SILICA (Respirable Fraction Exposure Limit =0.1 mg/rb3) Analysis of the coal boiler fly ash disclosed a crystalline free silica content of 28% in the combustion chamber fly ash. Because long-term exposure to crystalline silica can cause a chronic fibrogenic lung disease known as silicosis, several boiler house operators were spot checked for silica exposure while loading fly ash from the silo to the disposal trucks. A monitoring punp (drawing air at 1.7 lpro flow) was set up to capture only the respirable fraction of the dust using a cyclone collector and a PVC-5 filter. The filters were then laboratory analyzed for silica content. The results (as 10-hour TWA's) were 0.04 and 0. 16 mg/rn3. NCC 01312 Since one of the sanples exceeded the permissible exposure limit, a sign warning of silica exposure has been posted at the entrance to the silo unloading area. Boiler House personnel have routinely used the 3M - 8710 dust mask for protection from fly ash dust. This mask is also rated for protection against silica at the exposure level found and will continue to be worn during fly ash exposure. IV. TOLUENE (Permissible Exposure Limit = lOOppm) During 1988, personnel monitoring for Toluene exposure was done in the Polymer Chemicals Bldg. 712, the MBT-Crude Bldg., the Laboratory, and at Waste Treatment. The monitoring results continue to show that there is little Toluene exposure. Spot check monitoring will be done on a monthly basis for a representative operator from the X-70/Geltrol processes, and quarterly for a representative operator from each other Job classification that may be subject to Toluene exposure. TOLUENE EXPOSURE AREA NO. OP MONITORINGS AVERAGE PERSONNEL EXPOSURE fPFtP MBT-CRUDE Polymer Chemicals (712) PC Laboratory Wastewater Treatment PC Maintenance (in 712) 2 8 1 5 1 1.00 1.63 1.00 1.00 1.00 Several Toluene monitorings were also done as area sanples in the sludge dewatering building at wastewater treatment; to check for off-gasing from the sludge. The average exposure detected for the area was 5.20 ppm. V. ACETONITRILE (Permissible Exposure Limit = 40 ppm) For 1388, the acetonitrile expos'ire average in the 3114 Building (722) was 9.4 ppm. A quarterly spot-check monitoring is done of a representative operator in the area. Additional monitoring will be done whenever there is a process change or unusual situation that oould cause acetonitrile exposure. VI. METHYLENE CHLORIDE (Permissible exposure limit = 50 ppm) The American Conference of Government Industrial Hygienists (AOGIH) has lowered the permissible exposure limit for Methylene Chloride from 100 ppm to 50 ppm. A quarterly spot-check sample is done in the Accelerator Expansion Building for Methylene Chloride exposure. The 1988 monitoring results show the average exposure to operators in the 725 building to be 1.55 ppm. Monitoring will continue at the spot-check frequency unless problems occur. VII. HEAVY METALS (Etermlssible Exposure Limits: ) Cadmium -0.5 mg/m3 Chromium = (Hexavalent = 0.05 ragAd3 ) (Trivalent = 0.5 mg/ra3) Copper =0.2 rcg/m3 Lead = 0. 05 rag/in3 Nickel = 1 mg/m3 NGC 01313 Personnel in the Weld Shop, Maintenance Shop, and the Laboratory were monitored for exposure to heavy metals. A personnel monitoring punp ( 2 lpn flow rate) with an 0.8 micron, mixed-cellulose ester filter in a 3-piece cassette was used, samples were sent to an outside laboratory for analysis. The''e were no exposures exceeding permissible exposure limits. HEAVY METAL MONITORING AVERAGE EXPOSURE Cffig/m?) JDB CLASS CADMIUM CHROMIUM POPPER Service Shop Welder Maint. Shop (Lathe Operator) 0.00016 __ 0. 00032 0.00061 0.017 Lab Worker (Making up Premix) __ __ r.KAD 0.00013 0.00026 NICKEL <0.01 0. 15 __ VIII. FORMALEEHYIE (Permissible Exposure Limit = lppm) The CSHA has established a new permissible exposure limit for formaldehyde which is set at 1 ppn. Because of formaldehyde off-gasing from the paraformaldehyde used to manufacture 3114, eleven representative monitorings were done in the 722 building. The average formaldehyde exposure to 3114 process operators is 0.13 ppm. Warehouse operators in building 712 were also monitored because of the paraformaldehyde skids that are stored in the area. This group's average exposure is 0. 05 ppm. Formaldehyde monitoring as area samples in the warehouse gave an exposure average of 0.24 ppm. The only area that is currently posted with the CSHA warning sign for formaldehyde (required for area above 1 ppro) is the paraformaldehyde storage room on the 2nd floor of building 722. IX. VINYL CHLORIDE (Farmissible Exposure Limit = 1 ppm) All operators in the Poly and Dryer Building as well as the FYC Tank Farm are monitored for vinyl chloride exposure at least once per year. The schedule of monitoring then follows the CSHA VC1 standard which requires monthly monitoring for any exposure greater than 1. 0 ppm until two consecutive monitorings are less than 0.5 ppm. The employee need not be monitored again during the year if his annual monitoring result or the two consecutive monitorings are below 0.5 ppm. All VC1 ironitoring samples were collected on Reiszner gas badges. VINYL CHLORIDE MONITORING Year 1986 1987 1989 No. of People Monitored 315 248 314 1.79 1.06 1.15 % Greater Than 1 pod 40 21 27 30 58 48 nGC 01314 RESPIRATOR COMPLIANCE (POLY BUILDINGS Year No. Of Exposures Greater than 1 \au,, No. of Exposures Greater than 1 w/o Resrdrator Respirator (Vunnl i rwi 1986 1987 1988 131 53 72 49 63% 15 72% 24 67% The job class breakdown is as follows for Fbly Building employees exposed to greater than 1 ppro VCL without the use of a respirator. JOB CLASS MO. OF EXPOSURE Lo Sope Charge Operator Recovery Operator Pearl Charge Poly Bldg. Foreman 11 09 03 01 There were 13 vinyl chloride exposures in the Dryer Building during 1988 that were greater than 1 ppm (since the last exposure on 11/09/88, there have been no new non-compliance exposures in this area). The job class breakdown is as follows: JOB CLASS Dryer Operator Bagger Dryer Foreman HIGHEST EXPOSURE LEVEL 3.1 ppm 1.7 ppm 1.2 ppm NO OF EXPOSURES 09 * 03 01 Three of these employees had entered the ft>ly Building during their work shift. Since several of the Dryer Operators who were exposed to VCL above 1 ppro had opened and flushed out BT 9 and/or 10 during the monitoring period, airline hookups have been installed on the 2nd floor near the manheads of these tanks. Two short-term VCL exposure samples that were taken during this task (with BT exhaust in operation) showed only 0.67 ppm and 0.53 ppm. However, prior exposure checks using an OVA gave readings exceeding 1000 ppm at the open manheads when the ET exhaust was off. If BT 9/10 exhaust is inoperable, opening these tanks should be a respirator require task. For the year 1988, the overall Dryer Building VCL exposure average out of 93 samples was 0.51 ppm. During 1987 , 74 sanples gave an exposure average of 0.35 ppro. NGC 01315 VINYL CHLORITE EXPOSURE BY JOB GLASSIFICATION JOB CLASS Poly Cleaner PVC Tank Farm Operator HRC Ebly Cleaner Recovery Operator Pearl Charge Operator Past/LoSope Charge Dryer Operator Poly Bldg. Foreman Valve Cleaner PVC Bagger PVC Contract Employees (Baggers) Blending Charge Operator Silo Operator Dryer Bldg. Foreman Catalyst Make-Up PVC S&E Operator MONITORINGS 11 04 20 41 57 37 46 12 05 38 20 01 12 10 02 02 NO. Q AVERAGE (Fltll 4.15 1.81 1.42 1.40 1. 12 0.99 0.72 0.71 0.53 0.51 0. 44 0.43 0.33 0.28 0.27 0. 12 X. EMPLOYEE TRAINING As required by the 0GHA Hazard Conminicat-ion Standard (HAZCOM), training is given to employees who may be exposed to hazardous chemicals as new-hires before they start work in the plant, when they transfer to a different work area* whan a new chemical hazard is introduced into the Plant, and then on an annual basis as a refresher coarse. During 1988 , 306 Henry Plant Employees were given HAZCOM training. Two employees (PC & Maint.) missed the annual training and could not be scheduled into a makeup session. Hearing conservation training is given annually to all employees who work in areas where the noise level exceed 85 decibels. There were 158 employees trained during 1988. No employees missed the scheduled training sessions. XI. CONCLUSION The most serious industrial hygiene problems in the plant continue to be noise and vinyl chloride exposures greater than 1 ppn without respirator protection, particularly in the Dryer Building which is not a regulated area. In both the Fbly and Dryer Buildings these exposures seem to predominate in certain job classifications. Although many of the operators list "no known VCL exposure" for the monitoring period, I think that we need to look closer at the individual tasks that they perform during the work day. Soma of these tasks may already be "respirator required". In this case employee review training for respirator use requirements may be beneficial. Ln/E259 Diana Friesz 'VGcJ 3 f r, Dist- P. Donataccio K.J. Willings V. D. Marquis R. C. Linnenan M W. Reynolds M. A. Acterman J.P. Griffin D. L. Rys D.E. Giffin R. D. Webber W. J. GrudzinskL D. D. Moriarty J. D. Krumholz T.C. Patterson ME. Guyer S. Wiednan Den Gleghom (Cleveland) File ?SGC 013V7 TO: PROM: TP&-J, HAZARD COMMUNICATION DISTRIBUTION T. S. BIALKE DATE: kJ. 4/9/86 INDUSTRIAL HYGIENE PERIODIC PROGRAM STATUS REPORTS K Please add^Chris Andersen,) Geon Vinyl International Division in Cleveland to the distribution of ~yi :r periodic Industrial Hygiene Status Reports. Thank'you. TSB/kp 8148q cc: C. Andersen/P. Marason H. ffalteeate Toe S. Bialke NGC 01318