Document Ne29aw36qR44w94xMzGmge43g
DOW CHEMICAL U.S.A.
PLAINTIFF'S EXHIBIT
DOW-652
OYSTER CREEK DIVISION POST OFFICE BOX BB
FREEPORT. TEXA* 77541
INDUSTRIAL HYGIENE REPORT ________________________________ t-EPOPT NO. OYC IH-2-I
TITLE EVALUATION OF THE CHLORINE AND ASBESTOS EXPOSURES OF PERSONNEL IN THE CHLORINE PRODUCTION AREA AT THE OYSTER CREEK DIVISION
FILE NO._ OCD-2-1
DATE
May 11, 1976
AUTHOR G. R. GHntt
CHECKED
TDATE
/9 7A
SUMMARY
The chlorine and asbestos exposures of the personnel working in the
chlorine production area were surveyed and found to be well within
both the existing and proposed exposure standards. This Ireport gives
additional conclusions and recommendations as well as the actual
^
survey information.
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itf MIDLAND C."f__
FEB 1 i ioc-
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DOW CONFIDENTIAL
DISTRIBUTION:
Axe - Ind. Hygiene, Western Blair - 2020 Bldg., Midland Daniel - B-101, Texc.s Flores - 1707 Bldg., Midland Langner - 1707 Bldg., Midland Murray - Ind. Hygiene, Sarnia Oubre - O.C.D. Pero - O.C.D.
C. Sercu - Ind. Hygiene, East.
M. Swank - 1707 Bldg., Midland
C. VanMetre - O.C.D.
C-.
R. Webb - O.C.D.
: AN OPERATING UNIT OF THE DOW CHEMICAL COMPANY LA'- --
408782
2- -
PR03LEMS
This study was undertaken to evaluate the exposure of Unit II personnel to asbestos fibers and chlorine.
CONCLUSIONS AND RECOMMENDATIONS
A. Asbestos
1. Atmospheric concentrations of asbestos fibers were found to be well below the maximum allowable concentration of 2 fibers/cc (TWA) for all operations sampled.
2. The use of disposable coveralls and respirators
is good practice and should be continued.
|
3. A method of asbestos handling and pulping, which eliminates the practice of leaving open bags of asbestos on the cell covers, should be devised.
4. There is too much loose asbestos on the cell covers. This fiber has been wet and probably does not represent a health hazard, but a way should be found to eliminate it.
5. The transfer of bagged asbestos from the warehouse to the cell area is an operation where the potential for overexposure exists. The use of asbestos in polyethylene lined bags seems to have reduced the possibility of overexposure and the use of this type bag should be continued.
6. Training programs on the hazards of and proper handling techniques for asbestos appear to be very good.
B. Chlorine
1. Atmospheric concentrations of chlorine were found to be below the maximum allowable concentrations (TWA of Ippm) for all areas.
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408783
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2. The highest concentrations of chlorine were found in the secondary chlorine compressor area.
3. No suitable method for determining the peak exposure to chlorine has been found. Unit II personnel have been advised to use respiratory protection at the first odor of chlorine.
PROCESS
Unit II produces chlorine and sodium hydroxide by the electrolysis of sodium chloride brine. The electrolysis is carried out in Dow diaphragm cells which utilize an asbestos on wire screen diaphragm to separate the anode and cathode compartments. During the operation of those cells, holes may develop in the asbestos portion of the diaphragm. Such holes are undesirable since they effect both the performance and longevity of the cells. To plug these holes, a slurry of usbestos in water is added to the anode compartment of the cell. This procedure is known as "pulping" and involves the following steps:
a. A bag of asbestos is carried from the cell area storage location to the top of the cell tosbe pulped.
b. The bag is opened and the dry asbestos is wet with a hose.
c. The asbestos is dumped from the bag into a large plastic basket where it is slurried with water.
d. The slurry is added to the cell through a large funnel.
e. The area is washed thoroughly with a hose.
The major portion of the asbestos is stored in a warehouse which is some distance from the cell area. It is moved to a temporary storage location in the cell area by use of a forklift. This temporary storage area will hold about a week's supply of asbestos.
The chlorine which is produced in the cell area is collected under a slight vacuum. It is dried and goes through successive stages of compression and cooling until the pressure reaches a level at which the chlorine can be readily transported.
408784
-4-
DISCUSSION
Two job classifications were under study during the course of this study. The cell control technician (operator) is responsible for the day to day operation of the electrolytic cells. He generally works a straight day schedule. During the course of this work he is on top of or around the cells for several hours a day. He may handle asbestos every day, but the amount of time spent moving asbestos bags and pulping seldom exceeds thirty minutes and is frequently much less. All technicians who handle asbestos wear disposable coveralls and mouth bit respirators while doing so. The short lengths of time during which asbestos is actually handled gives an actual TWA exposure of far less than the concentrations given for pulping operations in Table I of the Data Section.
The chlorine technician is responsible for the operation of the chlorine cooling, drying and compression areas. During the day, he may also assist the cell control technicians. He works a rotating schedule (shift) and at night he is responsible for the operation of the cells.
The asbestos sampling covered only the cell control^technicians. '
They were considered to be the most frequently exposed
group because they handle asbestos almost every day. The chlorine survey included both job classifications and all
chlorine manufacturing areas.
^
Overexposure to asbestos fibers can cause asbestosis (a
disabling injury in which scar tissue forms in the lungs) and has been implicated in the formation of tumors of the chest cavity. The currently recommended maximum exposure is 2 fibers/cc for an eight-hour time weighted average (TWA).
^ ___
-ixi
Chlorine overexposure can be divided into two catagories.
An acute overexposure, such as could occur during a gas
>!
release, can lead to possible lung damage and death. A
-
chronic overexposure can lead to irritation of the respitatory
system producing a condition which has been referred to
as a "chlorine cold". The maximum allowable concentrations
f
are a TWA of 1 ppm and a ceiling level of 3 ppm. At any
concentrations above the ceiling level, respiratory protection .
should be used.
- .v*
CAMPLING AND ANALYSIS A. Asbestos
The samples being reported were collected during June, 1975 and January, 1997766. Breathing zone samples
408785
-5-
were collected in the warehouse area and the ceil area while asbestos was being handled. Technicians also wore personnel monitors while performing those portions of their jobs which did not require the handling of asbestos. These samples were collected to insure that there was no contamination of the work area from the adjoining temporary storage area. Area samples were collected in the storage areas to insure that levels there were not excessive.
Samples were collected on a Millipore 37 mm filter cassette having an exposed area of 855 sq. mm. A Bendix Micronair or MSA Model S sampling pump set to a flow rate of 1.7 to 2.0 1/min. was used to pull air through the cassette. Flow rates were measured with ap American Meter Division Model 115 Dry Test Meter. The fiber counts were obtained by the Microscopy Section of the Texas Division Central Laboratory.
B. Chlorine
The chlorine samples were collected on a bed of activated charcoal contained in a Pyrex drying tube. The sampled air was pulled through the charcoal bed with a Bendix Micronair or MSA Model S sampling pump set to a flow rate of 2 - 2.3 1/min. Flow rates were measured in the same manner as those for asbestos sampling. All chlorine samples were of the area type rather than personnel monitors. The decision to monitor in this fashion was made for the following reasons:
1. Having a personnel monitor with a glass sampling tube was considered unsafe.
2. While a personnel monitor gives information about exposure levels it does not provide information about the location(s) where the exposure actually occured.
For any type of job where there is a considerable amount of movement from place to place this is a necessary piece of information.
The measurement of the chlorine levels is based on the catalytic properties of the charcoal bed which converts chlorine to chloride ion. The chloride ion is extracted from the charcoal and titrated with silver nitrate. The titrations of these samples were performed by the Texas Division Central Laboratory using a coulometric method of end point detection.
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408786
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6- -
PRESENTATION OF DATA
Table I presents all the areas sampled and the results of these analysis. Also included is additional information such as total amount of air sampled and total fiber counts. Table II presents information about the chlorine sampling and results of the analysis of these samples. Table III shows how the information from Table II is used to determine a composite average concentration for various areas of the chlorine manufacturing facility. Table IV is a compilation of actual time spent in each area which, when combined with the composite average concentrations, leads to the TWA exposure listed. Figure I is an overview of the chlorine manufacturing facilities and areas surveyed. The circled letters represent the areas described in Table III.
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ASBESTOS SAMPLING LOCATIONS AND RESULTS
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408788
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TABLE II - CHLORINE SAMPLING LOCATIONS AND RESULTS
LOCATION
AIR PUMPED IN 1.
1. Cell covers - Series I
792
2. ' Cell covers - Series 3
702
3. Cell covers - Series 4
828
4. Cell covers - Series 6
720
5. Cell covers - Series 5
736
6. Cell covers - Series 7
640
7. Ground level between Series 5 and 8
805
8. Ground level between Series 1 and 4
700
9. South end of Series 8
817
10. Chlorine Scrubber Deck
840
11.
Near Chlorinated water pump
1053
12. North Side - Sump 1
920
13.
Between C-202 A/B
810
(secondary chlorine compressor)
14.
Between C-203 A/B
780
(secondary chlorine compressor)
15.
North Side of Terry Turbine (primary compressor deck)
897
16.
South Side of Terry Turbine (primary compressor deck)
840
17.
South Side of T-202 (drying tower)
966
18.
Between C-203 A/B
870
(secondary chlorine compressors)
19.
Cell Lab
1000
TOTAL ug OF Cl FOUND
385 151 743 491 568 518 342
526
CHLORINE CONC.; IN ppm.
0.17 ^
0.07 0-31
d&St
0-23 0.27
-28 0.15
0.26
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835 29
533
771 743
2177
1143
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121 1183
90
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9-15-76
408789
TABLE III - CHLORINE CONCENTRATIONS BY AREAS
AREA Cell Covers
Ground level around cells
Cell Lab
Chlorine Drying Coolir-.g and Compression
Inside Main Building
LOCATION FROM TABLE II
1 through 6
7 through 9
CHLORINE CONCENTRATI (COMPOSITE AVERAGE),
0.22
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0.25
19 11 through 18
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0.03 0.34
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408790
76
T A B LE I V CHLO RINE EXPOSURE LE V E LS-
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Main Building, Shop, Offices, Etc
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408792
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DOW CHEMICAL U.S.A. "7V3V
OYSTeR CHEEK DIVISION HOST OFFICE BOX BS
FREEPORT, TEXAS 77S41
INDUSTRIAL HYGIENE REPORT
TITLE '* EVALUATION OF THE CHLORINE AND ASBESTOS EXPOSURES OF PERSONNEL IN THE CHLORINE PRODUCTION AREA AT THE OYSTER CREEK DIVISION
FILE NO. PCD-2-1 DATE________May 11/ 1976 AUTHOR G. R. Gantt
CHECKED DATE '5&chtO/ (97
SUMMARY
The chlorine and asbestos exposures of the personnel working in the chlorine production area were surveyed and found to be well within both the existing and proposed exposure standards. This report gives additional conclusions and recommendations as well as the actual survey information.
|
|
,
DOW CON
DISTRIBUTION:
R. Axe - Ind. Hygiene, Western E. Blair - 2020 Bldg., Midland R. Daniel - B-101, Texas G. Flores - 1707 Bldg., Midland R. Langner - 1707 Bldg., Midland N. Murray - Ind. Hygiene, Sarnia R. Oubre - O.C.D. W. Pero - O.C.D.
C. Sercu - Ind. Hygiene, East. M. Swank - 1707 Bldg., Midland C. VanMetre - O.C.D. R. Webb - O.C.D.
AN OPERATING UNIT OP THE DOW CHEMICAL COMPANY
LZIC 0 01S
408793
-2-
PROBLEHS
This study was undertaken to evaluate the exposure of Unit II personnel to asbestos fibers and chlorine.
CONCLUSIONS AND RECOMMENDATIONS
A. Asbestos
1. Atmospheric concentrations of asbestos fibers were found to be well below the maximum allowable concentration of 2 fibers/cc (TWA) for all operations sampled.
2. The use of disposable coveralls and respirators is good practice and should be continued.
3. A method of asbestos handling and pulping, which eliminates the practice of leaving open bags of asbestos on the cell covers, should be devised.
4. There is too much loose asbestos on the cell covers. This fiber has been wet and probably does not represent a health hazard, but a way should be found to eliminate it.
5. -
The transfer of bagged asbestos from the warehouse to the cell area is an operation where the potential for overexposure exists. The use of asbestos in polyethylene lined bags seems to have reduced the possibility of overexposure and the use of this type bag should be continued.
6. Training programs on the hazards of and proper handling techniques for asbestos appear to be very good.
B. Chlorine
1. Atmospheric concentrations of chlorine were found to be below the maximum allowable concentrations (TWA of lppm) for all areas.
GcitOOOJLS
408794
2. The highest concentrations of chlorine were found in the secondary chlorine compressor area.
3. No suitable method for determining the peak exposure to chlorine has been found. Unit II personnel have been advised to use respiratory protection at the first odor of chlorine.
PROCESS
Unit II produces chlorine and sodium hydroxide by the electrolysis of sodium chloride brine. The electrolysis is carried out In Dow diaphragm cells which utilize an asbestos on wire screen diaphragm to separate the anode and cathode compartments. During the operation of those cells, holes may develop in the asbestos portion of the diaphragm. Such holes are undesirable since they effect both the performance and longevity of the cells. To plug these holes, i slurry of asbestos in water is added to the anode compartment of the cell. This procedure is known as "pulping" and involves the following steps:
a. A bag of asbestos is carried from the cell area storage location to the top of the cell to be pulped.
b. The bag is opened and the dry asbestos is wet with a hose.
c. The asbesuos is dumped from the bag into a large plastic basket where it is slurried with water.
d. The slurry is added to the cell through a large funnel.
e. The area is washed thoroughly with a hose.
The major portion of the asbestos is stored in a warehouse which is some distance from the cell area. It is moved to a temporary storage location in the cell area by use of a forklift. This temporary storage area will hold about a week's supply of asbestos.
The chlorine which is produced in the cell area is collected under a slight vacuum. It is dried and goes through successive stages of compression and cooling until the pressure reaches a level at which the chlorine can be readily transported.
6Z IC0001S
408795
DISCUSSION
Two job classifications were under study during the course of this study. The cell control technician (operator) is responsible for the day to day operation of the electrolytic cells. He generally works a straight day schedule. During the course of this work he is on top of or around the cells for several hours a day. He may handle asbestos every day, but the amount of time spent moving asbestos bags and pulping seldom exceeds thirty minutes and is frequently much less. All technicians who handle asbestos wear disposable coveralls and mouth bit respirators while doing so. The short lengths of time during which asbestos is actually handled gives an actual TWA exposure of far less than the concentrations given for pulping operations in Table I of the Data Section.
The chlorine technician is responsible for the operation of the chlorine cooling, drying and compression areas. During the dzy, ne may also assist the cell control technicians. He works a rotating schedule (shift) and at night he is responsible for the operation of the cells.
The asbestos sampling covered only the cell control technicians. They were considered to be the most frequently exposed group because they handle asbestos almost every day. The chlorine survey included both job classifications and all chlorine manufacturing areas.
Overexposure to asbestos fibers can cause asbestosis (a disabling injury in which scar tissue forms in the lungs) and has been implicated in the formation of tumors of the chest cavity. The currently recommended maximum exposure is 2 fibers/cc for an eight-hour time weighted average (TWA).
Chlorine overexposure can be divided xnto two catagories. An acute overexposure, such as could occur during a gas release, can lead to possible lung damage and death. A chronic overexposure can lead to irritation of the respitatory system producing a condition which has been referred to as a "chlorine cold". The maximum allowable concentrations are a TWA of 1 ppm and a ceiling level of 3 ppm. At any concentrations above the ceiling level, respiratory protection should be used.
SAMPLING AND ANALYSIS
A. Asbestos
The samples being reported were collected during June, 1975 and January, 1976. Breathing zone samples
010G0S
408796
-5
were collected in the warehouse area and the cell area while asbestos was being handled. Technicians also wore personnel monitors while performing those portions of their jobs which did not require the handling of asbestos. These samples were collected to insure that there was no contamination of the work area from the adjoining temporary storage area. Area samples were collected in the storage areas to insure that levels there were not excessive.
Samples were collected on a Millipore 37 mm filter cassette having an exposed area of 855 sq. mm. A Bendix Micronair or MSA Model S sampling pump set to a flow rate of 1.7 to 2.0 1/min. was used to pull air through the cassette. Flow rates were measured with ap American Meter Division Model 115 Dry Test Meter. The fiber counts were obtained by the Microscopy Section of the Texas Division Central Laboratory.
Chlorine
The chlorine samples were collected on a bed of activated charcoal contained in a Pyrex drying tube. The sampled air was pulled through the charcoal bed with a Bendix Micronair or MSA Model S sampling pump set to a flow rate of 2 - 2.3 1/min. Flow rates were measured in the same manner as those for asbestos sampling. All chlorine samples were of the area type rather than personnel monitors. The decision to monitor in this fashion was made for the following reasons:
1. Having a personnel monitor with a glass sampling tube was considered unsafe.
2. While a personnel monitor gives information about exposure levels it does not provide information about the location(s) where the exposure actually occured.
For any type of job where there is a considerable amount of movement from place to place this is a necessary piece of information.
The measurement of the chlorine levels is based on the catalytic properties of the charcoal bed which converts chlorine to chloride ion. The chloride ion is extracted from the charcoal and titrated with silver nitrate. The titrations of these samples were performed by the Texas Division Central Laboratory using a coulometric method of end point detection.
408797
-6-
PRESENTATION OF DATA
Table I presents all the areas sampled and the results of these analysis. Also included is additional information such as total amount of air sampled and total fiber counts.
Table II presents information about the chlorine sampling and results of the analysis of these samples. Table III shows how the information from Table II is used to determine a composite average concentration for various areas of the chlorine manufacturing facility. Table IV is a compilation of actual time spent in each area which, when combined with the composite average concentrations, leads to the TWA exposure listed.
Figure I is an overview of the chlorine manufacturing facilities and areas surveyed. The circled letters represent the areas described in Table III.
i cooois
408798
ASBESTOS SAMPLING LOCATIONS AND RESULTS
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408799
TABLE II - CHLORINE SAMPLING LOCATIONS AND RESULTS
1. 2. 3. 4. 5. 6. 7.
8.
9. 10. 11.
12. 13.
14.
15.
16.
17.
18.
19.
LOCATION
AIR PUMPED IN 1.
Cell covers - Series I
792
Cell covers - Series 3
702
Cell covers - Series 4
828
Cell covers - Series 6
720
Cell covers - Series 5
736
Cell covers - Series 7
640
Ground level between Series 5 and 8
805
Ground level between Series 1 and 4
700
South end of Series 8
817
Chlorine Scrubber Deck
840
Near Chlorinated water pump
1058
North Side - Sump 1
920
Between C-202 A/B
810
(secondary chlorine compressor)
Between C-203 A/B
780
(secondary chlorine compressor)
North Side -of Terry Turbine (primary compressor deck)
897
South Side of Terry Turbine (primary compressor deck)
840
South Side of T-202 (drying tower)
966
Between C-203 A/B
870
(secondary chlorine compressors)
Cell Lab
1000
TOTAL ug OF Cl FOUND
385 151 743 491 568 518 342
CHLORINE CONC. IN ppm. 0.17 0.07 0.31 0.23 0.27 0.28 0.15
526
0.26
835 29
533
0.35 0.01 0.17
771 743
2177
0.29 0.32
0.96
1143 108 121
0.44 0.05 0.04
1183 90
0.47 0.03
9-15-76
W i 20001S
408800
TABLE III - CHLORINE CONCENTRATIONS BY AREAS
AREA A. Cell Covers
B. Ground level around cells
C. Cell Lab
D. Chlorine Drying Cooling and Compression
E. Inside Main Building
LOCATION FROM TABLE II
1 through 6
7 through 9
CHLORINE CONCENTRATION (COMPOSITE AVERAGE), ppm
0.22
0.25
19 11 through 18
*
0.03 0.34
0
9-15-76
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FIGURE I - CHLORINE MANUFACTURING AREA
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