Document VGeZwkqmLgwQKbypVmQ7Jjkj4
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Interoffice Communication
To : Distribution
k
From : Jerald Uptain\j
Date : March 3, 1982
Subject : HONEYWELL CONTINUOUS MONITORING DATA VALIDITY STUDY
During the week of November 9, 1981, an audit of the Aberdeen Plant industrial hygiene program was conducted by T. Grumbles, L, Legendre, and S. Pitts. During the audit, the team expressed concern about
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excessive contamination of breathing air, as reported in the September, 1981 Continuous Monitoring Report. That report stated that 4.03% of the
time, VCM concentrations in stream if 7 (respirator air filter outlet)
amounted to ppm or more. The report also-stated that 5 ppm or more
was detected 0.28% of the time in stream if 10 (respirator air filter
inlet). The disparity between the two percentages was also questioned by the audit team.
* r
Following the audit, I checked the validity of the September, 1981
summary of data from streams if7 (respirator air filter outlet) and
#10 (respirator air filter inlet) of the "VCM Tank Farm" Honeywell G.C. unit. To do this, I made side-by-side comparisons of the monthly summary, the daily reports from which the monthly summary had been tabulated, and the original stripcharts from which data was taken for the daily reports. As a result, both the monthly summary and the daily reports were discredited for the following reasons:
1. The monthly summary had been incorrectly tabulated from the daily reports. Whereas the monthly report reflected 29 instances
(4.03%) of 5+ ppm VCM in stream if7, a recount from the daily
reports revealed only 2 (0.28%).
2. In spite of repeated attempts, I was unable to justify the high concentrations of VCM reported for breathing air in the daily reports. Although the daily reports reflected 2 instances (0.28%)
of 5+ ppm VCM in stream if7, I could find no such instances on the
stripcharts.
3. In addition, I found;
a. Obvious instances of chart misreading by operators. One common
mistake was interpreting stream #6 as though it were stream if7.
b. Cases where stripcharts were not always stamped daily as they are supposed to be. Also, some stampings were done at inconsistent times of the day.
The probelm of inadequate strip chart identification was found and addressed by the Safety Department in June, 1979. The department monitored progress in solving the problem until September, 1979. At that time, for EPA reasons, continuous monitors were turned over to Process Engineering.
VAB.0001113562
Distribution March 3, 1982
Honeywell Continuous Monitoring Data Validity Study Page 2
Since these findings made all of the past daily and monthly reports suspect, a program was begun to recheck hourly readings of breathing air VCM concentrations from all of the stripcharts saved since startup of the Honeywells in 1975. The work was done in the following manner:
1. All of the stripcharts which could be identified as containing data on breathing air were retrieved from storage and sorted into chro nological order.
2. Hourly readings were then taken from the entire length of each stripchart. This was accomplished by laying out each chart beside a scale marked with hourly divisions. In this way, we were able to overcome mismarkings of the charts noted above.
3. The data sheets resulting from the chart readings were filed chronologically in a large ring binder to segregate them from regular, daily reports.
4. All of the data was then summarized as shown in Table I (attached).
5. In addition to myself the stripchart reading was done by the following people, under my supervision:
Albert Barr Robert Bristol Dennis Knight
Charles Smith Charles Worlow
Several points concerning the data in Table I should be noted:
1. Over the years,two different Honeywell G.C. Units and three different sampling point locations have been used to monitor VCM in breathing air.
2. Several charts were not located. Whether they were lost or never marked with correct identification is uncertain.
3. The data in Table I represents the best available information on VCM contamination of breathing air and should be used in lieu of data aDneardntf in past monthly summaries.
Jerald Uptain tap c: JF, CRM, Department Heads
VAB.0001113563
TABLE 1
I
SUMMARY OF HONEYWELL CONTINUOUS MONITORING OF BREATHING AIR FEBRUARY, 1975 - JANUARY, 1982
LEGEND
G.C. Units:
1 - Large Reactor Area
2 - VCM Tank Farm
'
Sample Point Locations:
*
* *
1 - Breathing Air Line, Under H-I Reactor 2 - Respirator Air Inlet 3 - Respirator Air Filter Outlet
Year
1975 It fl II II II II II II
Month
Feb. Mar. Apr. May June July Aug. Sept. Oct.
G.C. Unit
1 1 1 1 1 1 1 1 1
Stream No.
10 10 10 10 10 10 10 10 10
Location
1 1 1 1 1 1 1 1 1
0-1 .0 No. %
1,0,-5. 0 No. T
Range, PPM VCM
5.0+ No. "1
71 540 511 464 459 461 516
NO N0 98.61 98.90 95.16 97.07 98.29 96.04 96.09
DAT A
DAT A 0 0+ 4 0.74 17 3.16 12 2.51 6 1.28 12 2.51 13 2.42
1 2 9 2 2 7 8
1.39 0.36 1.68 0.42 0.43 1.45 1.49
Total No. *1
72 546 537 478 467 480 537
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vmoooi 113564
ft i
Year
1975 11
1976 ft If 11 VI tv IV If It VI tl If
1977 VI II 11 u 11 11 IV n it M 11
Month
Nov. Dec. Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec.
G.C. Unit
1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2
Stream No.
10 10 10 10 10 10 10 10 10 10 10 10 10 10 4 4 4 4 4 4 4 4 4 4
%
4
Location
1 1* 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 2 2 2 2 2 2 2
TABLE 1 (Continued)
*
G.C. Units:
1 - Large Reactor Area 2 - VCM Tank Farm
Sample Point Locations:
1 - Breathing Air Line, Under H-l Reactor 2 - Respirator Air Inlet 3 - Respirator Air Filter Outlet
0-0.5
No.
A)
607 84.31 514 89.24 521 70.03 600 86.21 565 85.09 561 93.66 350 91.86 547 96.80 450 95.75 480 95.62 583 93.43
11 78,58 132 86.84 116 83.45 484 97.78 125 87.41 215 70.26
N0 141 97.92
N0 167 98.82 136 96.45 144 100.0
N0 N0 N0
0.5-1.0 "No7 "X
Range, PPM VCM_________________________________________________
1.0-5.0 "No:
5. Of
"No... T--
Total
No
46 6.39
33 5.73
100 13.43
62 8.91
42 6.33
22 3.67 -
20 5.25
13 2.28
13 2.77
8/ 18
1
1.59
2.88 7,14
10 6.58
14 10,07
7 1142
2 1,40
11 3,59
DAT A
2 1.39
DATA
1 0.59
5 3.55
00
DATA
DATA
DATA
62 29 115 33 53 15 10 11
6 12 20
1 9 5 2 16 46
1
1 0 0
8.61 5.03
15.46 4.74 7.98 2.50 2.63 0.92
1.27 2.39 3.21 7,14 5.92 3,60
0.40 11.19 15,03
5 0 8 1 4 1 1 0 1 2 3
1
1 4 2 0 34
0.69 0
0.59 0 0
0 0 0
0.69 0 1.08 0.14 0.60 0.17 0.26 0 0.21 0.40 0.48 7,14 Q. 66 2.88 0,40 0 11.12
0
720 576 744 696 664 599 381 571 470 502 624
14 152 139 495 143 306
i
144
0 169 0 141 0 144
VJlB.0001113565
T i ;1
Year
1978 II VI If It It If If II ft If If
1979 ft M II IV IV n
tv
n VI IV M If 11 If II If Tl
Month
Jan. Feb. Mar. Apr. May June July Aug. Sept. Oct. Nov. Dec. Jan. Feb. Mar. Mar. Apr. Apr. May May June June July July Aug. Aug. Sept. Sept. Oct. Oct.
G.C. Unit
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Stream No.
4 4 4 4 4 4 4 4 4 7 7 7 7 7 7 10 7 10 7 10 7 10 7 10 7 10 7 10 7 10
Location
2 2 2 2 2 2 2 2 2 2 2 2 2 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2
TABLE 1 (Continued)
i i
t
G.C. Units:
1 - Large Reactor Area 2 - VCM Tank Farm
Sample Point Locations:
I
1 - Breathing Air Line, Under H-l, Reactor 2 - Respirator Air ^nlet 3 - Respirator Air Filter Outlet
1 '
I
H L I
Ran PPM VCM
0--0.5 No. %
0.5-1 .0 No. %
1.0-5. 0 No. %
5.0+ No.
4 Total X No.
N0 DATA N0 DATA N0 DATA N0 DATA
1
i
1
t
1
-
4
t
i-
1
V
t4
L
N 0 DATA N0 DATA
1 1
*
i*
.#
b
i
N0 DATA
4 *
N0 DATA
4r
* 1
4
86 59.72 12 8.33 45 31.26 1
N0 DATA
i- 1
0.69 144
1
N 0 D A T A'
1 1
N0 DATA
'
m
N0 DATA N0 DATA
d
p>
i
1
1
142 85.55 153 92.17 494 95.92 515 100.0 699 96.42 725 100.00 448 98.24 456 100.00 417 98.58 422 99.76 105 97.22
108 100.00 691 99.71 693 100.00 683 94.07 677 93.24
17 10.24
6
11 6.63 2
14 2.72 7
00
0
9
1.24
17
00
0
7 1.54 1
00
0
5 1.18 1
00
0
3 2.78 0
00
0
2 0.29 0
00
0
19
2,62
19
15
2.07
19
3.61 1.20 1.36 0 2,34 0
0.22 0 0.24 0 0 0 0 0 2.62 2.62
4
1 0 0 0 0 0
0 0 0 1 0 0 0 0 5 15
0.60 166
0 166
0 515 0 515
0 725
0 725
0 456
0 456
0 423
0.24 423
0 108
0 108
0 693
0 693
0.69
726
2.07 726 ;^AB
*T
Year 1979
1 980
Month
Nov. Nov. Dec. Dec. Jan. Jan. Feb. Feb. Mar. Mar. Apr. Apr. May May June June July July Aug. Aug. Sept. Sept. Oct. Oct. Nov. Nov. Dec. Dec.
i
G.C. Unit
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Stream No.
7 10
7 10
7 10
7 10
7 10
7 10
7 10
7 10
7 10
7 10
7 10
7 10
7 ' 10
7 10
Location
3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2
TABLE 1 (Continued)
G.C. Units;
1 - Large Reactor Area 2 - VCM Tank Farm
Sample Point Locations:
1 - Breathing Air Line, Under H-l Reactor 2 - Respirator Air Inlet 3 - Respirator Air Filter Outlet
0- 0.5
No. %
664 720 724 744 542 550 534 534
459 459 523 523 608 618 547 548 621 623 572 570 705 702 523 578 428 465 490 493
92.22 100.00
97.31 100.00
97.83 99.28 99.62 99.62 100.00 100.00 100.00 100.00 98.38 100.00 97.50 97.60 88.09 88.37 76.88 76.61 97.92 97.50 90.49 100.00 91.46 99.36 94.77 95.36
0.5-1.0 No. %
0
L1n
Ranee. PPM VCM
.0 No. %
5.0 + No. %
Total No.
45
6.25
11
00
0
16 2.15 4
00
0
. 5 0.90 7
2 0.36 2
1 0.19 1
00
2
00
0
00
0
00
0
00
0
9 1.46 1
00
0
6 1.07 6
7 1.25 6
60
8.51
23
56
7.94
25
149 20.03 23
135 18.15 39
14 1.94 0
18 2.50 0
38
6.57
17
00
0
34 7.26 5
2 0.43 1
8
1.55
19
6
1.16
18
1.53 0 0.54 0 1.27 0.36 0.19 0.38 0 0 0 0 0.16 0 1.07 1.07 3.26 3.55 3.09 5.24 0 0 2.94 0 1.07 0.21 3.68 3.48
0 0 0 0 0 0 0 0 0 0 0 0 0 0 .2 0 1 1 0 0 1 0 0 0 1
n
0 0 0
0 0 0 0 0 0 0 0 0 0 0 0 0 0 0.36 0 0.14 0.14 0 0 0.14 0 0 0 0.21 0 0 0
720 720 744 744 554 554 536 536 459 459 523 523 618 618 561 561 705 705 744 744 720 720 578 578 468 468 517 517
Year
1981 IV
vv
It It II It II tl 11 IT IIa a IV 11 VI V1 V 1ft ft IT 1f
fT
t ft T1
ft ft 11
V I t
iV *I
1982 ft
V1
Month
Jan. , Jan. Feb.
t
Feb. Mar. Mar. Apr, Apr. May May June June July
*
July Aug. Aug. Spet. Sept. Oct. Oct. Nov. Nov. Dec. Dec. Jan. Jan.
G.C. Unit
2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2
Stream No.
7 10
7 10
7 10,,
7 10
7 10
7 h
10 7
10 7
10 7
10 7
10 7
10 7
-9
10 7
10
Location
3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2 3 2
TABLE 1 (Continued)
G.C. Units;
1 - Large Reactor Area 2 - VCM Tank Farm
Sample Point Locations:
1 - Breathing Air Line, Under H-l Reactor 2 - Respirator Air Inlet 3 - Respirator Air Filter Outlet
0-0 .5 No. %
607 617 158 165 622 623 665 673 566 568 644 645 458 457 376
356 631 635 413 410 587 585 413 413 358 342
87.08 88.52 77.45 80.89 95.98 96.14 92.34 93.61 98.95 99.30 99.37 99.53 99.56 99.34 95.48 94.95 97.79 98.43 99.52 98.80 99.83 99.49 99.76 99.76 98.90 94.48
0.5-] .0 No. %
Range. PPM VCM
1.0-5 .0 No. %
5.0 + No. %
Total No.
45
6.46
43
40
5.74
38
27 13.24 19
25 12.25 14
22
3.40
-2
20 3.09 2
13
1.95
37
10
1.49
33
4 ,0.70
2
4 0.70 0
3 0.47
1
1 0.16 2
1 0.22 1
3 0.66 0
7 1.86 9
15 4.21 3
10 1.58 4
8 1.26 2
00
1
4 0.96 1
1 0.17 0
3 0.51 0 1 0.24 0
1 0.24 0
2 0.54 1
11 3.04 6
6.17 5.45 9.31 6.86 0.31 0.31 5.56 4.90 0.35 0 0.16 0.31 0.22 0 2.39 0.28 0.63 0.31 0.24 0.24 0 0 0 0 0.28 1.65
2 2 0 0 2 3 1 0 0 0 0 0 0 0 1 2 0 0 1 0 0 0 0 .0 1 3
0.29 0.29 0 0 0.31 0.46 0.15 0 0 0 0 0 0 0 0.27 0.56 0 0 0.24 0 0 0 0 0 0.28 0.83
697 697 204 204 648 648 716 716 572 572 648 648 460 460 393 393 645 645 415 415 588 588 414 414 362 362
^B.0001113568
'T t ! *