Document QJo53B5MoGj1p4vGQq7ao2nRL
frugal * OPMC VCM MONITORING PROGRAf-j_REyjjw
i
OCTOBER 1900
1. OVERVIEW
Vinyl Chloride Monomer (VCM)
Employee exposure monitoring at DPMC presently consists of: (1) Fixed point area monitoring (2) spot grab sampling by means of plastic syringes and a GLC, (3) portable hydrocarbon detector use and (<1) personnel 8 hour time weighted average air sampling. This report represents a review of the data collected by personnel TWA "breathing zone" monitoring from January 1973 to September 25, 1980 and offers recommendations for future VCM personnel mcnitoring.
11 . QSliA REGULATIONS 29 CFR 1910.1017
(c) Permissible Exposure Limit 1 ppm - 8 hr. TWA, and 5 ppm - Ceiling
(j) Mon i toring
Reouired:
(i) Monthly if exposure exceeds 1.0 ppm TWA
(i i) Quarterly if exposure exceeds 0.5 ppm TWA
(; i i 1 Provision for discont inuino :::oni tor ino where levels are below 0.5 pjm
<C> l,ennissiblc rxpoiurc tirr.H. U) No employee may Be exooxe'cl" lo vinyl elilotlde :il concentration:: creator lluiii I ppm averaged over any B-hOur per ind. nnd
<21 No employee may be exposed lo vinyl chloride at concentrations creat or than 5 ppm averaged over any period not cxcccdiiw: 15 minutes.
(3) No employer may lx; exposed to vinyl chloride hy direct contact with licjuid vinyl chloride.
<d> Mijr.iuii-iuf}. Ml A program at initi:il immiiorinj: and measurement shall be itndcrinV.en in each establishmm: to determine if there is my rii:pluviT exposed. without regard to the tise of respirators. in excess of the net n:i level.
Where a determination conduct ed under paragraph (d)tli of this seeHi*:: .-.Iuim.-: any employee exposure;, u-ifhenst regard to the use of respira tors. in caress of the Action level, a 1-i'os:i ami for determining exposures for e.ieh such employee shr.l! be estab lished. Such a program:
d) Shall he repealed at least month ly where any employee is expo>ed. withmst regard to the u.-.; nf rcspir.v tni:;. hi excess uf the permissible expo!-u: e limit.
<:U .``-hall he rriiealrd not le.-e: t!:a:i tjur.rte: ly when* any employee. Is ex posed. without regard to the use of M-MurMi'r:.. hi execs/, of the lu-Uon level.
tiiil May he d:;;eriMl!m:rd for a:;y em ployee only . Si.-:i at least two conr-m: live monitoring determinations. made not le:e; than 5 uurfcun: days apart, shee-v rxpi-si;r es for that employer at dr i11*j>m the acti>:i level.
SCC
1-0993
REVIEW OF VCM EXPOSURE LEVELS
--------------------------
A. Summary Personnel TWA Exposure Data
j
*
SHELL PERSONNEL
NO . HEAS
NO. >.5
1930
300
(Jan.-Sept.25)
1979
626
13 (6:"-) 39 (6?.)
197S
J.1JS 14 39
36 (7S) 93 (6-:-)
NO. >1.0
9 (37) 25 ()
22 () 56 '()
/*. IS'
ince January 1978, 1439 personnel TWA samples have been collected on hell personnel. An additional 350 samples were collected on contractor employees, (Table 2). This surveillance lias averaged 54 samples per month, with typically 44 measurements being collected on Shell employees. Presently ell Shell operators and assigned maintenance personnel are monitored on a monthly basis. Monitoring coverage for Shell employees has included 20 separate job categories.
TABLE 2
CONTRACTOR PERSONNEL NO. MEAS - NO. > . 5
1930 (Jan.-Sept..25)
1979
56 159
0 5
1973
J_35 350
j 3 u:.)
NO; >_l_._0 0 3 3 6
SCC 1-0?94
Includes Shutdowns, Startups and normal operating conditions
fcc*a
**\
v Ur'
Overall, S6* of all Shell TWA personnel monitoring data collected during the spec ified time period has been below 1.0 ppm (Table 1). Approximately one half of the
samples collected which exceed 0.5 ppm also exceeded 1.0 ppm, TWA. Ninetyeight percent of Contractor exposure data- is below 1.0 ppm (Table 2).
Seventy-five or Sit of the 93 measurements on Shell employees which exceeded 0.5 ppm were collected on the 4 job categories of (1) Edc (100) Operator, (2) Gauger/Utility Operator (3) VCM Loader-Site 1(1 and the VCM 200 Operator, (See Attachment 1). In 1980 sampling coverage to 9/25/00 for these 4 job categories represented 41*'. of all samples collected.
Representing the job categories with greatest apparent exposure potential, a detailed evaluation of the measurements collected on these <1 job categories has been completed. Table 3 below presents a statistical sumnary of the data. A detailed review of all 75 samples analyzed to be in excess of 0.5 ppm is provided as Attachment 2. Where available, information pertaining to the cause of exposure has been incorporated.
tie. Samo 1 o s (n) No. >. 5
laz (100) Operator
177*
12
173 13
No .>1.0
3 A
TABLE 3 (x) Avq.
j_g . 73
Sample Std. Dev. Sx
.44 7.9
Sx _ : x - (cv)v'-n 95X Conf. Interval
.13 - .25 ppm 0 - 1.94 ppm
Gaucer/Uti1itv Ooerator 155 20
VO* Loader - Si te 11! 90 33
12 21
. 30
1.2 . i - (%
.17 - .55 ppm ,47 - 1.37 ppm
VO: 200 .0iw-iilil *
7 > > \ .s
0.09 - 0.55 ppm
w 75 44
*Conf:Jence interval tor population mean calculated without a 3/78 105 - pi" result included.
see
1-0995
*
dc (100) Operator: 13 of 173 or approximately 77. exceeded 0.5.ppm. For 19S0 ,2 of 37 or 57. exceeded 0.5 ppm (none exceeded 1.0 ppm). Based on this data the mean average.exposure level has been calculated to lie between .13 and .25 ppm.
Gauger/Uti 1 i ty Operator: 20 of 159 or approximately 127. exceeded 0.5 ppm. For T5S0 S of 32 "or TS7 exceeded 0.5 ppm {157 exceeded 1.0 ppm). Based on this data .the mean average exposure level has been calculated to lie between .17 and .55 ppm.
VCM loader - Site 111: 33 of 17$ sample or approximately 77 exceeded 0.5 ppm. For 19S0, 7 of 22 or 327 exceeded 0.5 ppm (137. exceeded 1.0 ppm). Based on this data the mean average exposure level has been calculated to lie betv/een .47 and 1.37 ppm. Leaks during tank car loading were most frequently reported as sources of exposure exceeding 1.0 ppm.
VCtt 200 Operator: 9 of 1G6 samples or approximately 5% exceeded 0.5 ppm. for 1930, none exceeded 0.5 ppm. Based on this data the mean average exposure level has been calculated to lie between 0.09 and .55 ppm.
3. Ten Point "OSHA" Area Monitoring Data
While area monitoring data may not always relied actual employee exposure, a limited review of available data collected by the 10 area sampling stations was completed to further assess exposure potential to employees working in the VCM unit.
Scsec on a nominal 23 samples per day. per sampling station, data has been $ujwr.ari:ed for 154 day period Hay - September 1930, (See Attachment 3).
!n sunxarv, only 1S6 measurements above 0.5 ppm were recorded. These "alarm" readings represented approximately 0.5".. of all samples. Measurements greater than 1.0 ppm represented less than .27 of all samples collected.
facings above 0.5 ppm were recorded on 39 of the 154 days; on 40 days levels in excess of 1.0 ppm were recorded. No trend was found which indicated one month as having more "alarm days" than another.
The greatest number of measurements above 0.5 ppm were recorded for sampling stations No. 5, 7 and 10; the sampling si roam;: that had the greatest number o: "alarm days" wore noted to be 6, 7 and 10. A review of the available records indicated several sources of emission including plugging of bleeders, pump seal leaks, overhead condenser leaks and leaking sample bombs.
see
1-0996
5
C. (Hiring the time period of 1/78-9/25/SO the VCM monitoring data indicates that OPMC is routinely in compliance with the 1.0 ppm TWA standard on all
s*** iob categories'except tho : Gauger/Utilitv Operator.
VCM Loader - Site 111 Operator
For the above time period, measurements in excess of the 0.5 ppm action level have been recorded on 12 Shell and 2 Contractor jobs. Personnel and Area Monitoring suggest that occasional VCM excursions occur due to nonroutine events {leaks, fugitive emissions, etc.) thereby resulting in 3 hr. samples in excess of 0.5 ppm.
OShA monitoring requirements (Section 11) specify "representative" monitor ing monthly where exposures exceed 1.0 ppm (TV/A) and quarterly where exposures exceed 0.5 ppm. Sampling may bo discontinued where consecutive sampling shows exposure levels below 0.5 ppm, TV/A (sec. 1910.1017 (d) (iii)).
CSHA requires that a monitoring program meeting the minimum requirements outlined above, be relied upon to "determine if there is any employee exposed... in excess of the action level" and to determine when controls are required. Further, exposures in excess of either the 1.0 ppm 8 hr. TWA or the 5.0 ppm Coiling must be controlled by feasible engineering, work- practice controls and/or respiratory protection. For the monitoring conducted, the exposure of each employee must be .represented, however, all employees need not be sampled.
The frequency and coverage of exposure survei1 lance presently afforded for Vinyl Chloride at OPMC exceeds the 0SMA requirements for 8 hour TV/A sjonicoring, however, during the specified time period. Short tenu {ca. >5 minutes) monitoring has not been performed to assess actual peak exposure levels during tasks of higher exposure potential. Short term ceiling measurements would document compliance with 1910.1017 (c)(2), the 5.0 ppm coiling limit, and/or identify peak exposures on job categories generally within the 1.0 ppm TWA limit.
cits'
see
1-0997
errai
IV. KECOMHENOEP VCM PERSONNEL MONITOR I NG PROGRAM
6
Based on the revie'wof the VCM exposure data which has been completed, it is recoiunended that the sampling frequency and coverage be adjusted to reflect current needs and past exposure history...
Changing from the present extensive program of monitoring all employees monthly, the revised routine surveillance program to be implemented would place the greatest emphasis where the exposure potential is highest. Overall monitoring would be decreased, but still maintained at a level in excess of CSKA requirements.
Consistent with current Industrial Hygiene practice and in compliance with 0SKA`s requirements, it is further proposed that future monitoring address representative employee exposure on a job category basis. While monitoring coverage will be rotated so as to include all employees on at least a yearly oasis, not all employees would he monitored routinely eg. monthly.
The proposed monitoring program will:
1. a. provide as a minimum, quarterly TWA monitoring for job categories historically associated with "low relative exposure potential", eg. HC1:N Operator , Oxy Operator.
h. provide for the monitoring of all employees on at least an annual basis.
c. provide ror increased monitoring to two Limes per month where quarterly monitoring shows 8 hour 1WA exposure to bo in excess of the 0.5 ppin action level. Monitoring will continue to be performed tv/ice monthly untii A such 1WA measurements are analyzed to be below the action level (2 months).
2. Provide as a minimum, monitoring two times per month for job categories historically associated with higher relative exposure-potential . eg. VCM Loader-Site 111, (Tauger/Ul. i 1 i tv Operator.
3. Provide for an "initial", ami as a minimum, semiannual monitoring for peak exposure levels during specific work activities, 'Routine work duties on eacn job category having potential exposure in excess of 5.0 ppm ore to po scheduled for evaluation.
4. Provide tor better utilization of Industrial Hygiene personnel without compromising the integrity of the surveillance program. At the present time, approximately 90`3 of 1 Industrial Hygiene Technicians time is dedicated to VCM exposure survoi1 lance. At the end of 1981 the VCM monitoring program would again he reviewed so as to address the needs identified at that time.
5. Prov.de for flexibility, lion-routine exposure, surveys will be performed on a request basis SO as to address rh,m|r\ in work practices, controls or production.
see 1_099B
fraa
I
6. Personnel monitoring of assigned Contractor personnel will continue f'*S to be performed monthly.
7. Shutdowns and Startups, as well as other major maintenance activities
will continue to be handled on a ease by rase basis. Typically, all
personnel are individually monitored during turn-arounds.
S. The recommended frequency of routine VCM monitoring is presented as Table 4 below.
TABLE 4
RECOMMENDED VCM MONITORING PROGRAM
Job Category
Minimum Sampling Frequency
Twice Monthly
Quarterly
Monthly
EOC (100) Operator
X-
Gauger/Uti1ity Oper.
X
VCM Loader-Site III
X
VCM 200 Operator
X
Shift Foreman (VCM)
X
faci1itv Oper.-Site 11 i
X
Foreman Maintenance
X
VCM Cperations-Staff
.. X
Quality Control Lab Tech.
X
O.w ISO Operator
X
L Shift Foreman-Site 111
X
HCIii
V
instrument Mechanic
A
Assigned Shell Maintenance Personne1
X
;;: v t
ScilermaLer Csc: -e ra 1 Ma i n tena nee ripe?itter
;n> trument Meehanu: !Xl
^ *\ * o
X X X X
X
see
2.-0999
v
tXSSi
ATTACHMENT T
SUMMARY OF VCM TWA EXPOSURE DATA: SHELL EMPLOYEES
(January . 197S-Supter.iln-r 2 5, 1 9SO) Monitored 197S, 1979 nnJ 19S0
Job Cntcv.orv
1. EDO Operator (100 Operator)
2. Oauger/Ucilicy Operator
3. VCM Loader - Sice 111 H . VCM 200 Operator 3. Shift 'foreman (VCM) o. facility Operator -
Site 111 7. roror.'.aa (Maitenance) s 4 VCM Operations - Stars' 9. Quality Control Lab
Technic 1 an 10. Cxy 130 Operator 11. Shift Toreman - Site 111 12. KCiS 13. 1 v.s t rumen t Mechanic
No . o f Samp l es 17 S
159
90 1.00 152 J I .1
12 2S 99
IVi )
200 V.)
SU of all samples above 0.5
{>!>'
Mo. > .5 ppm
r ( 7.32)
\ 20 (12.57.) f 33 (37.OX)
( 5.47)
7
1
0 L ( 3.67.) 3
2 0 2 0
Moni cored 19 7S i 1979
Jk K ee t i *: i .an ) _ Mechanic j. ils' i ierrr.a e r
Helper 5. Mara inist 6. . * . . a. 7. }'ipci it tor
i 12
4 *> 4 l ; a
0 0 0 0 l 0 L ( 4.57.)
see
1-1000
2
ATTACHNKNT 1 SUMMARY OK VCH TWA i-XPOSUKK DATA: CONTRACTOR Kt-U'I.OYI- ES
(January, 1978 - Sepcumlivi' 25, 1980)
Job Cstecorv
No. o f 8 amp 3 en
No. > ,
Mini 1. Boilermaker 2. Foreman 3. General Maineannnee L. I'ip of i et o.v :j .. ,, eilite i. 1 ns t rumen c Meehani e si; no xy . ?aincer
.102 38 28
1 K.
LG
3 0 0 5
0
0
i
see
1-1001
ATTACHMENT I!
Job Catooorv VCM Gauger
Date 1/12/7S
Name Mayter
Sample Her.u 11
1.2
Exposure Due To
Sampling light ends from light ends dryers
VCM Gauger VCM Gauger VCM Cauger VCM Cauger VCM Gauger
6/07/7$ 8/10/70 8/11/78 S/13/78 2/1*1/79
O'Valle Srai th Rodriquez 0`Valle Thompson
3.9 0.7 0.9 0.5 2.7
Sample col lection
. Mocking in light ends iced pump
VCM Gauger VCM Gauger
G/26/79 9/0-1/79
levies Hooker
.G 1.7
Unde termined/routine task?
VCM Gauge r
9/24/79
Stokes
6.2
Leaking sample bomb station fittings in rundown area
VCM Gauger
12/04/79
Novak
2.3
Uncle* tormi n-_-d /KOC tank car loading
VC.M Gauger VC.M Gauger
12/05/79
4
12/19/79
Hillcy Hooker
1 .3 .5
Undetermined/routinu tasks
VCM Gauger
01/11/60
Doe
1. 3
Leaking sample bomb valve
VCM Cauger VCM Ca-agor
C1/24/GO 01,'74/SO
Doe Hedger
o.v 1 .3
Sample station inlet valve leak
VCM Gaucer VCM Gauger
04/02/50 04/16/60 .
Weathers Dues
0.5 1 2.1
Untie-1 : era i ned / rbu L i nc tasks
VCM Gauger
07/09/60
: i rti'.an
1 .5
Undetermined/routine tasks
VCM Gauger VCM Gauger
Q7/l(*/sQ 05/29/60
Me Dill f. i rman
0.5 1 . 0
Lincoln fittings jt storage spheres sample col leer ion
No'. O:
Msusu^ov, :*nis analy;,*i*a 1 e Iv -1.0 ; >1 -in .<<<' >t i cause c>
i ig.it -d ;; t`
SCC 1-1002
h*t>i
Catceorv IOC 100 Oper.
coc 100 Oper.
Date 02/0S/70 02/1-1/73
NO PC Dartarn Hayter
IOC 100 Oper.
roc 100 Oper. roc 100 Oper.
03/03/70
03/03/73 OS/11/78
KLex
Maytor Koppcl1o
roe 100 Oper. roe 100 Oper. roc 100 Oper. roe 100 Oper. roc 100 Oper. r.oc 100 Oper. roe 100 Oper.
coc 100 Oper. VOl 200 Oper.
OS/11/73 0S/12/78 03/12/7B OS/13/7S 03/14/73 11/15/73 04/09/30 03/03/30
J l. /1 0 / 7 0
Thompson Holt rate Thompson HightovcV N: l ron Hayter Jones
C 1 .t rk
vex 200 Oper. vex 200 Oper.
0 3 / 1 U/78 03/11/78
C lark u*i 1 i i a:nson
vex 200 Oper. vex JC0 Oper. vex. 200 Oper.
03/20/78 0 1 / 16 / 7 3 10/31/79
Willi ar.>s o >i Castaneda i-o Liard
vcm 200 Oper.
vex. 200 e.wv. vex. 200 Opor.
12/02/70 U /1 3 / 7 9
1 2 / 1: / 7 o
JCMICS
I-'.aga 1 1 ar. M.iga 1 l an
Uer.u 11 0.6 5.5
105.0
0.G 1.3
0.5 0.5 0.5 ` 1.0 1 .3
1.0
0.9 0.5 l .9
* ll l .2
2.3 . <i
2.3
3.5
: *j. 3
l .9
Exposure Occ To
High concentration in spent caustic pumped to V-6104 Sompl ing C-6101 reflux pump
Losing water wash seal legs during C-C10L wash
*
Washing V-G V02
Unplugging tup tap of l.AJ. on C-G2I1
Hlock valve leak while flushing V-C2C3 Instrument transr.ittc
Occcmt an 1 no. t: or: VCM,
IlCl columns Wash 1 ng VCM co 1 urr Gauge glass broker.
I'-f.XO] pu:r.:> sea! leak
N 01 C : v.e.i ju ; _': h ms c.uj$o o
a to
-1.0 : pm .i: !Hil i live:, t : *;.i i i-ti .
see
1-100
xabk 3
A11ACHKLNT tl
Job Category
Date
Home
Sample Result
Kxoosurc Due To
VCM Loftier Site III
01/23/73
Hi 1 ton
4 .9
Leaking loading hose and swing joint
VCM loader Site ill
02/14/70
Jackson
1 . 1 Leak.ing flex hose at Spot 10C52
VCM Loader Site III
06/20/7S
Carter
2.2
Leaking sample valve on tank car at 10VS3
VCM Loader Site III
07/13/7S
Coleman
3.9
-
VCM Loader " Site 111
07/26/73
Ur own
3.5
Liquid leak from Sensall device at 10V53 {premature disconnec tion of flex hoscj
VCM Loader Site 111
VCM Loader Site III
09/20/70 12/13/7G
Wo1 ford Cornett
1.5 .9
Faulty slip tube needle valve
VCM Loader Site III
12/20/70
Hi 1 ton
.9
VCM Loader Site III
01/18/79
Kanos
2.9
Tank car valve leak
vex Loader Site III
01/24/79
Mulcare
0.5
VCM Loader Site III
02/13/79
Kennedy
0.7
vex Loader Site III
VCM Loader Site III
02/21/79 03/19/79
Cornet t Aiub re r.
5.6 IS.9
Leaking tank car clip tube valve
Leaking tank car slip tube valve
VCM Loader Site III
03/22/79
Kanos
2.6
Leaking JanesLury valve on purge lino
vex Loader Site III
04/17/79
Anbres
0.0
vcm Loader Site 1 11
04/23/79
Kamos
1.6
HI coder valves on liquid line adapter
VCM Loader Site 11:
vcm Loader -
site in
04/26/79 03/11/79
Kennedy All en
0.9 0.6
see
1-1004
Job Category
VCM Loader Site 111
VCM Loader Site III
VCM Loader Site HI
VCM Loader Site ill
VCM Loader Site 11!
VC.M Loader Site 1II
VCM Loader Site HI
vcm Loader Site HI
vcm Loader Site 111
vcm Loader Site 111
VCM Loader Site III
VCM Leader Site Hi
vcm Loader Site III
VCM Loader -
s i t c ;::
site :: i
-
A11ACHMIKI I I
Date 0 !i / 1 6 y 7 9
Name Ambres
07/02,09
Kennedy
Samp] C Kesu 11
1 .2
0.7
07/10/79
Ambros
1.4
07/12/79
Kamos
t. 0
08/01/79
Kennedy
08/07/79
Kamor
OS/15/79
Hi 1 ton
10/17/79
Aril) re r.
1 .0 . f.
:. i I! . 9
01/28/GO
Arconenux
01/30/SO
Arcenoaux
01/31/30
Dinghnm
2.5 1 .1 1.1
02/12/00
Uinglwm
02/26/S0
liinghani
03/12/SO
Mahan
0S/1S/S0
Wright
0.0 2. a 0.0 0.9
Kxoosurc Due To Leaking tank car slip tube valve
Undetermined/tank car unloading
Leaking tank car ss 1 ip tube valve
Leaking tank car slip tube valve Leaking tank car slip tube valve Undetermined/tank car 1oading Leaking liquid valve on tank car Leak et liquid lino connection on tank car
Leak at load valve and line on tank car
see
1-1005
'A
cast
ATTACHMENT 11 I DPMC A KM A vcm monitoring DATA 5/1/30 - 9/3i/an
S c rcam No.
No. Alarms Kenorted
*1 -2 *3 *s *S *6 *7 *9 *9 *10
9 19/10-5/31
13 15/5-6/5}
7 (7/15*6/61
12 (9/5-6/301
23 110/1*5/91
20 19/19-5/3)
37 (9/5-5/S)
15 (9/26-5/21
20 (9/2 2-5/31
30 (9/26-5/61
No. Days Af recited
3 10
4 7 H 13 17 U 14 2\
VCM Area Levels
Avr,. Alarm Moos. Max.
No . > l .
1 .20
3.1 2
2.00
>10.
5
2.03
4.1
5
1 . 3G
7.2
4
.06
1.7
6
1.19
3.8
5
1 . 52
>10.
10
1.82
>10.
6
1.02
3. 1 C
1 . ?6
8.0
15
* Scream ,5
1 2 3 6 5 6 / S
9 10
OSKA 10 POINT MONITORTNC SYSTEM
10* NE of E1K Kx K-6101 by P-610G 10' NK of Vent scrubber Control Room 5' E of V-6105 L.K. Accumulator by P-6105 20' SK of HCL Stripper Column C-620-5 3' U of HCL Stripper Column C-620A 5` NE of HCL Column C-6202 Below ami N end of Quench Column Accuir.u Lacov V-6201 3* KE of Quench Column C-6201 (Knrnnce Area) Yanh farm pump pad i'. of 1`- oGOA !'
Area
100 100
100 150 200 200 200
200
Utility
see
1-1006