Document VGzLaY5r3ze39bmZ79oegpKnN

ENVIRONMENTAL HEALTH SURVEY FOR 1985 CHLORINATED METHANES PLANT LOUISIANA DIVISION Submitted by: R. J. Bordelon DO 0B9860 conftofnttw. 1 CHLORINATED METHANES PLANT INDUSTRIAL HYGIENE JOB ANALYSIS A. introduction The Plaquemine, Louisiana Chlorinated Methanes Plant was monitored during 1985 in a routine and continual survey of the chemicals and noise present in this block. Listed below are the chemicals plus noise with their respective standards: Chemical Standard (TLV) Methyl Chloride Vinyl Chloride Methylene Chloride Chloroform Carbon Tetrachloride Methanol Ethylene Dichloride B-trichloroethane 1,1 Dichloroethane Dimethyl Ether Propylene Oxide Noise 25 ppm 1 ppm 100 ppm 10 ppm 5 ppm 200 ppm 10 ppm 10 ppm 200 ppm 400 ppm 20 ppm 85 dBA B. Conclusion from 1985 Survey Employees in the CMP block were monitored using personnel monitors. Most were monitored two or three times during the year. As in the previous years the data reflects that em ployees are within the threshold limits when performing their routine jobs. People are provided with and required to wear proper protective equipment when a job has the potential of exposing them to levels which may exceed the standards. c. Monitoring Results - Routine Work Personnel monitoring using charcoal adsorption tubes was em ployed to cover the jobs for the following chemicals: methyl chloride, vinyl chloride, dimethyl ether, methylene chloride, chloroform, carbon tetrachloride, ethylene dichlo ride, 1,1 dichloroethane, propylene oxide, and B-trichloroethane. To monitor for methanol, tubes filled with acti vated alumina were used. A total of 63 samples revealed the following results in ppm based on TWA (over a 4 hour period). Chemical Stan- # of High/ dard Samp. Job Average High/ Xndiv. Sample Methyl Chloride 25 7 OT 3.7 OT 12.7 Vinyl Chloride 1 63 All <0.01 All <0.01 Dimethyl Ether 400 63 All <0.1 All <0.1 Methylene Chloride 100 4 Loading 9.8 Loading 31.5 Chloroform Carbon Tetrachloride 10 5 4 Loading 5 Contract Maint. 1.7 Loading 9.0 Contract Maint. 6.9 44.8 Ethylene Dichloride 10 6 SOT Instrument 0.3 5 Instrument 0.1 B-Trichloroethane 10 63 All <0.1 EDO 0.3 Propylene Oxide 20 6 SOT 0.3 SOT 1.5 1,1 Dichloro 200 63 All ethane <0.1 All <0.1 Methanol 200 7 OT 0.6 OT OS EDO 1.1 1.1 1. 1 -2- DO 0R98<sa CONF TDFNTTA1 C. Monitoring Results (Cont'd) In '85 we used a personnel monitor to check for chlorine ex posure levels in the block. In the past we had relied sole ly on area samples as we use for HCL and H2SO4. Not every one was monitored due to the limited availability of this one monitor. The people working the jobs most susceptible to CI2 exposure were monitored. Samples were also taken on areas where the possibility of CI2 vapors existed. A total of 15 samples were collected, with two of these being dis carded due to malfunctioning of the monitor. The TLV for chlorine is 3mg/m^ or 1 ppm. Monitoring results in ppm follow: Job OT No. Samples 2 High High Instanteous 15 min. avg. 1.35 0.05 TWA <0.01 SOT 4 1.50 0.07 0.07 EDO 2 0.60 0.03 <0.01 Loader Area ~ C-805 vent Scrubber Area N/E corner of WHB 3 1 1 0.25 <0.01 0.05 0.40 <0.01 0.03 <0.01 <0.01 <0.01 -3- DO 0R98F9 CONFTDFNT IA( C. Monitoring Results (Cont'd) Monitoring for hydrochloric acid and sulfuric acid was con ducted by scrubbing air with distilled water as the scrubb ing agent, usually for a duration of 7-8 hours per sample. The scrubber was strategically placed in areas which were downwind of any possible HC1 or H2SO4 vapors. A total of 19 samples were taken. Highs in mg/m^ Chemical Hydrochloric Acid Standard 3 7mg/m High High Job Average Area Reading R-600 Area 0.21 R-600 Area 0.31 Sulfuric Acid 3 Img/m R-200 & R-300 R-200 & R-300 Area 0.28 Area 0.31 -4- 00 089870 gonftdfnttal D. Analysis Review INDUSTRIAL HYGIENE JOB ANALYSIS VERSUS OP HYGIENE STANDARD Standard 100% 50-100% 25-50% 10-25% <10% Methyl Chloride Vinyl Chloride Methylene Chloride Chloroform Carbon Tetrachloride Methanol Ethylene Dichloride B-trichloroethane 1,1 Dichloroethane Dimethyl Ether Propylene Oxide 25 ppm 1 ppm 100 ppm 10 ppm 5 ppm 200 ppm 1 0 ppm 1 0 ppm 200 ppm 400 ppm 20 ppm - - _ - - 1 - - 1 12 - - 13 - - 13a - 1 12 1 - 11 - - 13 - - 13 - - 13 - - 13 - - 13 - - 13 Noise 85 dBA - 1 3 45 TOTAL 02 4 6 144 % of TOTAL JOBS 0.00 1.28 2.56 3.85 92.31 Data based on TWA, excursion monitoring is excluded, a This represents 13 job classifications with the average exposure levels to methylene chloride being less than 10 ppm or <10% of the standard. -5- DO 089871 CONFTDFNTTAL E Noise - By Job Job # of Samples Average Dose % Average Maximum dBA dBA Operations Technician Sr. Operations Technician Operations Specialist Shift Supervisor EDO Clerical (includes Computer Tech) instrument Technician Laborer Contract Maintenance Material Controller Technical Chemist Loading 6 5 9 6 2 1 5 2 8 1 4 2 3 24 78 112 25 78 111 08 71 112 11 74 111 68 89 120 01 50 105 07 70 110 14 83 106 38 83 115 01 58 100 10 72 106 06 71 106 20 79 112 -6- D 08997 8 CNFJD8Nr IAt. CMP NOISE SURVEY BY AREA Area Office Control room Lab Instrument shop Warehouse Distillation, ground Distillation, upper V-800 filters Acid area R-600 area K-350 area HCL purification, ground (outside chainarea) HCL purification, upper R-250 area, ground Lewis unit deck Upper decks R-200 & R-300 area E-200 & E-300 deck deck fans Waste heat boiler & D-1 area C-500 area K-1002 (outside chain area) T/T load rack T/C load rack Check tanks T-814, T-104's, T-100, &T-101 areas 11/21/85 DBA 58 61 62-64 60 70 82-92 76-90 80-82 81-87 80-84 84-93 82-88 79-86 83-87 83-93 73-91 80-87 77-81 92-95 79-86 79-91 88-101 75 70-78 79-87 70-84 -7- 00 089873 OONFTDFNTT Al. ENVIRONMENTAL GOALS FOR 1986 1 - Monitor operators more closely to determine if respiratory equipment is adequate for the jobs they are performing. In the meantime, look at whether the equipment is really need ed for the particular job at hand. 2 - Get input from operators as to the possibility that certain jobs are being overlooked as potential causes of exposure. 3 - Do more excursion monitoring since many jobs are of short duration. 4 - Work with loading people to solve the fogging they have when they use the Scott-O-Vista. 5 - Look closely at noise problems which were generated by new equipment and/or modifications in our block. 6 - Monitor for amylene and cyclohexane, especially when opera tors inhibit check tanks. 7 - Monitor the loading and unloading of honeywagons as well as cleaning of these honeywagons. 8 - Do extensive monitoring of open-dome loading. 9 - Monitor venting from check tanks. -8- DO 089B74 CONFTDFNTTAl 1. For organic vapors collected and desorbed with CS2* Instruments - Hewlett Packard 5890 gas chromatograph with FID and Spectra Physics 4270 integrator. Conditions a. Temperatures 1. injector - 200C 2. detector - 250*C 3. Column - initial of 40*C programmed to 105*. b. Column - J & W - DB-1701, 30M, 1.0 micron film. c. Range - 1 d. Sample size - 1.8 ul injected with split injection. e. Calibrated weekly, blanks prepared daily. 2. For methanol vapors collected on alumina and desorbed with distilled water. Instruments - Varian Vista 44 chromatograph and Vista 401 data system. Conditions a. Temperatures 1. injector - 250* 2. detector - 270* 3. column - 160* operated isothermally b. Carrier gas flow - 42 cc/min. c. Column - 16' x 1/8 " od Porapak Q 50/80 mesh d. Range setting - 11 e. Attenuator - 1 f. Sample size - 1.2 ul 9- Calibrated weekly. blanks prepared daily VO 089875 OONFTDFNT TAi -9" JOB DUTIES BY CLASSIFICATION CHLORINATED METHANES PLANT 1985 Operations Technician (OT) He conducts sampling rounds in the finished products and distillation area. He also walks through the area checking temperatures, pressures, pump seals, etc. He will also perform lubrication checks. Generally, three rounds are made on each twelve-hour shift. Senior Operations Technician (SOT) The SOT is responsible for the reaction area. He performs basically the same duties in this area as the OT does in his area. In addition, he also collects check tank samples and performs lab analysis on them before trans ferring the finished product to the storage tanks. Operations Specialist (OS) There are two operations specialists on each shift. One serves as the control board operator while the other one performs duties wherever needed. He covers vacation relief and personal illness for all job classifications including shift supervisor. Shift Supervisor (SS) The shift supervisor is responsible for overseeing all personnel on his shift. His primary goal is to make sure that the plant is run safely and efficiently. Expanded Day Operations (EDO) This is a very versatile group which performs minor repairs, maintenance, and small fabrication jobs. They serve frequently as safety observers for "Hot Work" and vessel entry jobs. All OT's, SOT's, and OS's rotate through this job every three months. (The EDO job duration is three weeks.) Material Controller The material controller is responsible for ordering necessary suppli s for daily operations and special projects. He also maintains shelf item inven tories. His duties require him to spend very minimal time in the opera tional area. 0 089876 Co^tdfnttal I. Monitoring Equipment Used in the Survey A. For Chemicals 1. Personnel Monitoring MDA Pump, model 808 DuPont pump, model P-200 Sipin pump, model SP-1 DuPont constant flow sample calibrator for checking flow rates Dow LA Division Chlorine Dosimeter 2. Area monitoring Gillian pump, model HFS 113A B. For Noise 1. Personnel Monitoring DuPont dosimeter, model MK-2 2. Area Monitoring Edmont-Wilson dosimeter, model 60-510 Dosimeters calibrated on DuPont Audio Dosimeter Calibrator model C--114 -10- DO 089877 CONFTDFNTTAl