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VCM MONITORING - WORKPLACE ENVIRONMENTS dispersion VINYL RESIN UNIT SOUTH CHARLESTON PLANT ,
SUMMARY
Pursuant to Part 1910 - Occupational Safety and Health Standards, Emergency Temporary Standard for Exposure to Vinyl Chloride, Section 1910. 93q, effective April 5, 1974, personal monitoring was initiated at the subject location on March 11, 1974. Detailed sampling and analytical methods appear in Section XI of this`report.
Personal monitoring records are documented following this summary.
In addition to personal identification of employees and monitoring results, job
tasks which are either suspected or known to be associated with significant
exposure potential are noted.
_
Monitoring results obtained by use of a continuously operated gas chromato graph, maintaining surveillance of ambient air at nineteen (19) strategically located sampling points, are also presented. (See descriptive list and unit plot plan for locations.) In addition to serving as an excellent leak test monitor, the instrument provides an insight to potential personnel exposure directly related to sp/ecific job tasks and work practices. Other instrumentation used to aid in control strategy (leak testing) are the Miran Infrared Spectrophotometer, JbW TLV Sniffer and the Century Organic Vapor Detector.
With the advent of the Emergency Temporary Standard, a Management directive was issued regarding strict enforcement of appropriate respiratory protection use by all. employees when VCM concentrations are suspected or at any time known to exceed 50 PPM as previously determined by monitoring methods described above.
Anticipating a dramatic change in permissible exposure and, having already identified most inherently affected areas, e. g., opening, cleaning or sampling reactors, provision of respiratory protective equipment was in progress prior to the effective date. Attached are memos identifying the affected areas and job'tasks and instructions pertaining to use of respiratory equipment. Appropriate revisions, deletions or additions will be made to the listed work practices as the result of future studies and implementation of engineering control.
W. C. Young/jve 7/12/74
UCC 034756
LOCATION OF VC1 SAMPLE POINTS FOR GAS CHROMATOGRAPH
.1 Between VC1 Filters and C-31 .2 Control Room - 2nd Floor
3. Between C-37 and C-39
4. Between C-41 and C-43
5. Between and North of G-46 and C-47
6. Between C-33 and C-34
7. Between and South of C-34 and C-36
8. Between C-38 and C-40
9. Between C-42 and C-44
10. At Dryer Switch Bank
11. Over Sump at Latex Tanks Switch Bank
12. At 400# Filter Station
13. Between C-33 and C-34
14. At 200# Filter Station
15. At 125# Filter Station
16. Between C-39 and C-40
--
17. Between C-43 and C-44
18. Dryer Control Board
19. Between Homogenizers and 61 Compressor
20. Check Sample
200# Level 200# Level 125# Level 125# Level 200# Level 200# Level 200# Level 125# Level 125# Level Pad Level Pad Level Pad Level Pad Level Mezzanine Level Mezzanine Level Pad Level Pad Level Compressor Room Compressor Room 100 PPM
JLW/cd/jve
UCC 034757
4-5-74
SAFETY NOTES
A new temporary standard outlining personnel exposure to Vinyl Chloride goes Into effect 4-6-74. This standard states that no persons shall be knowingly exposed to VC1 concentrations greater than 50 ppm.
We have at the present time many operations which cause VC1 concentrations greater than 50 ppm. Therefore, until otherwise notified it is MANDATORY THAT THE FOLLOWING PROCEDURES BE CARRIED OUT USING A FRESH AIR SUPPLIED BREATHING APPARATUS.
(See Supplementary List)
A. CHARGING OPERATOR.
1. 2. 3. 4. 5.
. 6.
Dumping cat into cat pot. Cleaning the VC1 filters. Cleaning the homo suction filters. Venting down the charging line. Cleaning the Sarco homo suction filter. Decanting 2805 VC1 tank.
B. DRYER OPERATOR
1. Changing Dollenger manual filters.. 2. Switching Latex tanks at dryer switch bank. 3. Getting Latex sample to run total solids. 4. Blown gasket No. 1 or No. 2 MG pumps (shut down pump and get out
of room). 5. Wherever Latex is discharged to atmosphere by opening a valve or
breaking a flange connection.
C. TRANSFER OPERATOR
1. Changing manual Dollenger filters. 2. Backwashing Dorr Oliver & Cuno filters. 3. Cleaning 2940 foam trap. 4. Dumping broken pots. 5. Switching hose connections at Latex tank switch bank. 6. Washing Latex tanks (in particular while draining the wash H2O). 7. Collecting a total solids sample. 8. Wherever Latex is discharged to atmosphere by opening a valve or
breaking a flange connection. 9. Dumping Latex tank neals.
UCC 034758
2.
D. UTILITY FITTER
1. Opening an a/c dump valve. 2. Opening an a/c/manhead. 3. Starting the air out procedure prior to entry of laborer to clean. 4. Breaking any line which normally handles VC1 liquid or vapor
regardless of whether or not it was purged. 5. Blanking No. 57 & 61 compressors. 6. Installing sunction ring into reactor. 7. Washing a/c`s.
E. UTILITY OPERATOR
1. Switching No. 52 & 61 compressors. 2. Changing Dollenger manual filters in dryer control room. 3. Switching dryer feed lines at dryer switch bank. 4. As felt necessary by yourself or foreman.
F. BOARD OPERATOR
1. Changing vent station filters 2. As felt necessary by yourself or foreman.
G. LABORER
1. While cleaning on pad. 2. While dumping reactor scrap. 3. As felt necessary by yourself or foreman. 4. Cleaning out a "set-up" reactor or a reactor with large amounts of
scrap.
H. SAFETY MONITOR 1. As felt necessary by yourself or foreman.
I. OPERATIONS DAY MECHANIC
1. Dismantling Cuno filter to remove and clean filter media. 2. Repacking and cleaning homogenizers. 3. Dismantling No. 3 dryer feed pump and cleaning. 4. Tightening VC1 pump packings (such as premix pumps under C-4S). 5. Dismantling the Dorr Oliver filter for repairs. 6. As felt necessary by yourself or foreman.
J. WEIGHMASTERS
1. Cleaning on autoclave pad. 2. As felt necessary by yourself or foreman.
UCC 034759
3.
K. MAINTENANCE PERSONNEL 1. As directed by unit foreman.
As a temporary measure several portable breathing tanks have been placed throughout the trouble spot areas.
1. At the 125# autoclave level. 2. At the 200# autoclave level. 3. Between the dryer and Latex tanks switch banks. 4. At the diyer control room desk. 5. Inside the compressor room near the homogenlzers.
Twelve masks are available for use-- simply plug them in and breathe. Extra 50-foot long high pressure hoses are located in the 2nd floor control room if needed. When using these masks be sure to watch the supply pressure carefully. A full tank of compressed air will last about 8 hours so don't be afraid to use these systems. Only Blue Air cylinders can be used for breathing air supply. Clean all face masks with iso propanol immediately after use and place back into plastic bag. Additional plastic bags for masks are in Jack Moss's office.
We hope that we can eliminate these greater than 50 ppm potential exposure ar as in a timely manner. Our unit has been given about $400,000 to correct our problems. Our first job will be to install a permanent fresh air breathing header with about 20 out lets and 2 masks per outlet. Attached is a sheet listing the outlets I have in mind. Please feel free to add more if necessary.
Iam sorry for all the notes, but I had a lot to say.
db Attachment
D. A. Ellwood Unit Safety Coordinator
UCC 034760
FRESH AIR SUPPLIED BREATHING MASK CABINET
(2 Masks plus 2-50 foot hoses per Loc.)
1. South between C-46 & 47 reactors. 2. South between C-48 & 49 reactors. 3. South between G-34 & 36 reactors. 4. North between C-33 & 35 reactors. 5. North of C-31 by handrail east of west 2nd floor control entrance to Bldg. 193. 6. South between C-38 & 40 reactors. 7. South between C-42 & 44 reactors. 8. North between C-37 & 39 reactors. 9. North between C-41 & 43 reactors. 10. - Pad level under & between C-47 & C-48 reactors. 11. Pad level north of C-33 reactors. 12. Pad level north under C-37 & 39 reactors. 13. Pad level north under C-41 & 43 reactors. 14. Pad level south of 2954 H2O tank. 15. Pad level between the Latex tanks and dryer swltchbanks. 16. Inside compressor room around No. 1 dryer filters. 17. Inside compressor room by No. 61 compressor & homos. 18. Mezzanine level by No. 25 reactor filters. 19. Pad level north of C-48 reactor. 20. Pad level between C-40 & 42.
UCC 034761
Job Identification
Symbol
CO-1 -2 -3 -4 -S -6 -7
JOB TASK PER JOB TITLE
CHARGING OPERATOR (CO)
Dumping Catalyst into Catalyst Pot Cleaning the VCM Filters Cleaning the Homogenizer Suction Filters Venting Down the Charging Line Cleaning the Sarco Homogenizer Suction Filters Decanting 2805 VCM Tank Whenever VCM is Discharged to Atmosphere
DO-1 -2 -3 -4 -5 -6
DRYER OPERATOR (DO)
Changing Dollinger Manual Filters Switching Latex Tanks at Dryer Switch Bank Getting Latex Sample to Run Total Solids Blown Gasket. #1 or #2 MG Pumo Blowing #57 Compressor Tracifier Trap Whenever Latex is Discharged to Atmosphere
TO-1 -2 -3
-4 -5 -6 -7 -8
TRANSFER OPERATOR (TO)
Changing Dollinger Manual Filters Backwashing Dorr Oliver or Cuno Filters Transferring 2940 Tank Foam Trap Switching Hose Connections at Latex Switch Bank Dumping Broken Pots Washing Latex Tanks (Draining Wash Water) Collecting a Total Solids Sample Whenever Latex is Discharged to Atmosphere
UF-1 -2 -3 -4 -5 -6 -7 -8 -9
UO-1 -2 -3 -4
UTILITY FITTER fUF)
Opening Reactor Dump Valves Opening Reactor Manheads Starting Air-Out Procedure Prior to Entrv Blanking #57 & #6 1 Compressors Installing Suction Ring into Reactor Breaking Any Line which Handles VCM or Latex Washing Autoclaves Drilling Condenser Tubes Chancing Drver Soravs
UTILITY OPERATOR (UO)
Switching #57 and #61 Compressors Changing Drver Filters Switching Drver Latex Feed Lines Whenever Latex or VCM is Released to Air
BO-1 -2
L-l -2 -3
SM-1 JLWillis/ra
BOARD OPERATOR (BO) Changing Vent Station Filters Whenever VCM is Released to Air
LABORER (L) Cleaning Reactors Dumping Reactor Scrap While Cleaning On Pad
SAFETY MONITOR (SM) Bucketing Out Scrap from Reactor After rinaning
Job Title Charging Operator
Dryer Operator
Transfer Oner tor
Utility Fitter
Utility Operator
Board Operator Laborer Safety Monitor June 17, 1974
UCC 034782
inr
CHROMATOGRAPH AVERAGES (5/10/74 - 6/20/74)
Graph I - PPM Average Graph U - Above 50 ppm Frequency
per day
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AVERAGE VCM CONCENTRATION (PPm) PER WORKPLACE AREA4' tino JOS TtTjLL
FfXEO MUtTI PLE SAMPLING POINT VFA" H-AME IONIZATION DETECTOR
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VCM MONITORING-WORKPLACE ENVIRONMENTS_ DISPERSION VINYL RESIN UNIT - BLD6 1^0
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514-9573
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PiZlCHhL noUiUHlttE
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VCM MONITORING - WORKPLACE. ENVIRONMENTS dispersion vinyl Resin unit - bldg iao CHAR61N6 OPERATOR
514-9573
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PFeSrtvJflL K0(v)i'Tf(!|M6 RECCED - VCrO tfJ u)Cgkf>lf)cE eNtfiECtfMEKj'TS
CH^ecoAL TtlSE METHOD
Z 36>~30 ~ 3Z01/
P. W. Harris
NUMBER OtHSS
10(3 TITLE. C har^f Cpermtor
DEPT. 08*00
DATE M-IS-TH
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CONCEti nat oh r fpn < l
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514-9573
EMPlOYfE
DATE
PCkSCWAL MCNITORj^G RECORD -- VCt*\ !M We^ptAce EWIKONMEMTS
CHARCOAL TUBE t*\ETHOJ)
J?3h ~" 5*j6 Z.
R.p. Tar-lew NUMBER Qi4tt
1015 TITLE ChiryVg Cptraior
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CD^\C ENTPlTlOH. pm_
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6. t f'Pm
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034786
oo 514-9573
PERSONAL MONITORING RECORD -VCt*\ <N WORKPLACE ENV/CONK\6RTS
CHARCOAL7U8E METHOD
2
Employee e.l, &ri^. 3r.
number e^g
job title ctiarv*g c^ratcr
DATE
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6f i| R< M fi*tl Re 11
Vf/\ MCNITORINS-workplace environments DISPERSION VINYL RESIM UNIT -- 6L0G WO
_______________OPCR*moHS MECHANIC____________________ _
0 1590
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514-9573
PiECSCMAL M6NITCRIMG CtCKO - VCM im UClxflACE ItfViZCtiWEHfS
CHARCOAL Ti^GE. METHO)
5Z1-ZL-U.S8
Employee h. p. Geiii
n^mbe cos^c
^ofe_xcL^^_^g^lf*!ii_jiigAgig_-JD.LP'Ei-_^L_--
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514-9573
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3-14-74 ^-74 3-26-74 1-26-74 H-n-H 4-23*74 4-23-14 4-26-74. 4-3C-14
6 -11-74
employee
1
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f, n. Util >n
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n
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VCfA mONIT>RIN6 - WORKPLACE ENVIRONMENTS
Dispersion yinyl resin unit - buxs iro
TRANSFER OPERATOR
number
job task performed
concentration, ppm
D >S*3
c OSS3
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t 0 553
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PfRSCNAL MONITORING RECORO-VO/\ in workplace environments CHARCCAl TtfftE fAE-lHOO
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514-9573
1
EMPlCYEE
PERSONAL M0NU0R1N6 tfECOgO - VOl fW WORKPLACE. flJi/U?Ct{MENTS
CH4R.CGAL TOlil t*)7H0D
2 33-/W3SO\
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NUMBER OOS55
5yQr.Br TITLE
Transfer Operator
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1
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PERSONAL t'AONITCRlNS KEXCRQ - VCtA IN WORKPIACE N W/OJrtMENTS
CHARCOAL TUSE. POET HOD
2ZH- 10-7714-
r , r\^ cs CdTtn
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1
DATE
4-21 -1 4 H-21 -1 H
JOfi TAS PEf FORK >
C( lNCM r*AT ew f p/0
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514-9573
!
PERSONAL K(0UITCRIM6 RECORD - VCM IN V>(ORtC PLACE ENV/lRONtAENTS
CHARCOAL TUQE IWETH0O
U 3 " / H ~3 L S' i.
c.r'U'ktJ'ftt L. U anam aim nun C.1S
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4-4-74 4-4-74 4-4-74 4- fl-74 4-11-74 4-19-74 4-IS-74 4-16-14 *5-2114 S-23->J
5 -23-14 5 -21-14 6 -1-74 3 - lfc-74 S-lt-N
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dryer operator
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PERSOMAL MONlToetNlG RECORp - S/CtA IN WORKPLACE ENVtROH INVENTS
CHARCOAL 7U&E METHOp
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514-9573
PERSONAL I^ONnORiMG RECORD-VCN) IN WORKPLACE W/ONN]WTS
CHARCOAL TUBE. t*\THDO
ZZ3' ZH~ ^3^*0
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514-9573
l_______
1
PERSONA). MONITORING RECORD - VCM IN WORKPLACE ENVIRONMENTS'
CttKRCOAL TUBE METHOD
33-
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514-9573
1
,
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DATE
4-l- 14 S- it- T + S - it- 1 +
PERSONAL MONITORING RECCRO-VCn IN WORKPLACE ENVIRONMENTS
CHARCOAL TUBE METHOD
232' *32 - H
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514-9573
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Pc*<;cmal MOM ITC (ZING RECOJZ0-VCM IN WORKPLACE FMY/eOHMM7b
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2 3 L " 30 - 77>2
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514-9573
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235 ~0 I ~ Z~I &>>
514-9573
PERSONAL WONlTCRtHG RECQCO VC^l iM WOUKft.ACt. C'NViRC/'iMtNTS
CHARCOAL TUBE METHOD
233-IH-34S2
EL M[' 1PrLOrV*Y' 1EUEL-. 1. Dit, S<ihndaimnohnimn
NUMBER OI*Tfc
JOB TfTLE. flc-rd Open-tor
PPT. oesoo
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3*25- 14 3-2S- I*# 4 - 4 - 14 4 - 4 - 14 5-it- 74
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>14-9573
1
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PERSONAL MONHOR-lMG RtCCUO - VOM (N WCKP(-/Xt KV/(f?ONMfINTS
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514-9573
i
DA' r f H - 2h - n
PW0MAL MOhllTORlhlS RECORD - VOM im WORKPLACE MlKOHMeHTS
CHARCOAt TO0E. METHOD
23(0-10- 7724.
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514-9573
l
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034807
Jfl-H -lfl-74 -25-7^ -zs-m *2. -2-1H -I4-1H
I-22-7H 1-V1H
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VCK\ MONITOPONG - WORKPLACE ENVIRONMENTS DISPERSION VINYL RESIN UNIT - &LO& ISO
UTILITY OPERATOR
oia<
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514-9573
i
* 1 '
PtRSOis/AL M0NIT6RIM6 RECORD - VCM IN WORKPLACE Nvt RO^MENTS
CHARCOAL TP8E f^THO0
Z'bZ " 2 V -
202
EM PL 9VE1L E.A.Frashcr______ NiM8ER
__________ 1Q& TIT< F Uftlitn CV>e-a^e>r
DATE
JOB 17)5 (SL PE ZfPR 9D
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514-9573
1.
PtfcSCMAL MONITCEIaKS RECCED-V/CM IN WORKPLACE Cawjmwments
CHARCOAL TUBE METHOD
HOS-Zto-S Z?S
EMPLOYEE F.<5. Groves NUMBER OWl**
JOS TITLE Dtlli'ti Op*e*lor
DEPT. OifSOO
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H-L 1H 4-2 14
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514-9573
1
1
6 RECORD - VCAA /W WORKPiACfc BNVt RONW ENTS
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514-9573
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DA1E-
3-12-74 i -12 - 7* 2 -H - 7i 1 - M - Tf 3 -20 - 7t 7 -ec -14 3-21-74 J -2/- 74 3-.M- 7<f 1 -24-74 4 - 8 - 14 M-*-74 H - >0 - 74 4-1O -74 4 - it - 7 <* u - f - 7 <|
4 -/5 - 74 */ -<5-74 *f -<7-74 *1 .25-14 4-26-74 4-26-74
4-26-7-,
V-30-74 1-30-14 6-12-74 6 -13-74-
EMPLOYEE
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NUMBER
TOQ TASK PCRFCPMEO
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1
PERSONAE MONITORING RECORD - VCM IN WORK PLHCE N\/t8.0*1 HeuT*
CHARCOAL TOQE METHOD
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PRSe>MA*_ MONITORING RECORD- V^M IN WORK PEACE gN\ZlfZOtJME*lTS
CHf\RCC/\L 'TOQE. METHOD
232- 24 " 5^ 5
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514-9573
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IN WORKPiLACE N\/HZ CM HBuTTs"
CHARCOAL TUBE METHOD
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514-9573
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PERSOMAJ- MONITORING RECORD - VCM IN WORKPLACE N\ZlR.C*iH&JTS
CHARCOAL TOGE METHOD
23 4
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