Document ZnX04RXJLVb7oJQxBDGw5mB6p

LOUISIANA DIVISION INDUSTRIAL HYGIENE REPORT AN OPERATING UNIT OF THE DOW CHEMICAL COMPANY VECTOR SBC PLANT Department LAP-VECTOR 93.01 File Number 10/24/93 Date TITLE: Evaluation of Employee's Exposure to Noise, Cyclohexane, Styrene, Isoprene, Heat Stress and associated Industrial Hygiene activities at the Louisiana Division Vector SBC Plant, Plaquemine, Louisiana during 1992. J) f~ > ^ yj ~ x -J _1 t.i i / ' Reviewer's Signature Superintendent SUMMARY: During 1992, personal time weighted average (TWA) and/or excursion exposure to Noise, Cyclohexane, Styrene and Isoprene were evaluated. A heat stress evaluation was conducted to determine the heat conditions for specific tasks performed in the Finishing Building during the warmer weather of the year. These tasks were cleaning the expeller die, changing filters on E2530, changing the screen on E-2520 and unplugging CY-2520 cyclone. Results of this evaluation are published in separate report LAD-VECTOR 92.02 dated 10/1/92. (Continued on page 2) DISTRIBUTION: PLAQUEMINE: K. Hasenbeck* T. Holder Dr. G. Kusch C. Holmes* B-2304 B-807 B-2303 B-3302P MIDLAND: S. Dombrowski B-1803 R. Stevens J. Sampson M. Mitchell* G. Townsend* B-4350 B-4350 B-807 B-6650 `Cover Sheet Only RESTRICTED FOR USE WITHIN DOW DO A 1.13886 CONFIDENTIAL Several recommendations in this report supported a plant effort to get three (3) exhaust fans installed in the finishing building and five (5) floor fans strategically placed in the work areas. This project was completed August, 1993. Analytical results for cyclohexane, styrene and isoprene were provided by L. Almo, Environmental Services lab, and results reported under reference numbers 1387 and 1388. The results of employee full 12 hour shift average noise exposure for each job assignment monitored in 1992 are listed below: (expressed as a percentage of the allowable daily dose). These results are presented in Table 1. Operations Specialist Safety Technician Lab Technician Shift Supervisor Warehouse operator 32% 15% 10% 14% 34% The noise exposure were below the 50% action level. Hearing protection is worn in posted areas with noise levels greater than 90 dBA. An area noise survey of the material handling area was conducted in September, 1992 to review the noise levels in the blower areas after a noise reduction measures were taken. (See figures 1 and 2. ) Area sound pressure level measurements raged from 92 to 103 decibels. It is significant to note that the decibel readings around blowers B-1540A and B and 640A and B decreased by two decibels. These areas are designated as mandatory hearing protection areas since they are at or above 90dBA. This area has been designated as a double hearing protection area and the proper warning signs have been installed. There was one employee at the Vector SBC plant that experienced a work related Standard Threshold Shift. Potential exposures to Cyclohexane were found to be less than Ippm for the job classifications. There were no detectable amounts for Styrene and Isoprene. The results for Cyclohexane are well within the exposure guidelines of 300 ppm 8 hour TWA. The written Hazcom program and MSDS manual were updated to include new chemicals that were used in the process, laboratory chemicals, janitorial supplies, and welding rods. The written Respiratory program was reviewed and there were no policy changes. The Hearing Conservation, Personal Protective Equipment programs were updated. Training was completed for Hazcom, Respiratory, Noise, Heat Stress and Radiation. RESTRICTED FOR USE WITHIN DOW 2 DO A 110887 CONFIDENTIAL PURPOSE As a part of the continuous effort to provide a healthy and safe work environment for the personnel of Vector SBC Plant, a program to evaluate employee's exposure to noise and heat stress was conducted in 1992. This report addresses the work performed including recommendations for 1993. An ongoing in-plant industrial hygiene program is also planned. CONCLUSIONS 1. The results of employee full 12 hour shift average noise exposure for each job assignment monitored in 1992 are below the 50% action level which is well within the requirements of the OSHA Hearing Conservation Program. All personnel are part of the Dow Hearing Conservation Program which includes an annual audiogram. Hearing protection is worn in posted areas with noise levels greater than 90dBA. 2. Several areas within the Vector SBC plant have hot zones which were determined in an area survey. Radiant heat plays a major role in an employee's overall heat stress exposure. A review of the OSHA illness report and the Louisiana Division medical reports revealed that no one in the plant experienced a heat related illness since the startup of the plant. The results of this survey are published in a separate report LADVECTOR-92.02 dated 10/1/92. 3. Chemical monitoring was completed for those job classifications with priority ratings of 1, 2, or 3 according to the Chemical and Physical Agent Inventory. Additional monitoring is needed for butadiene unloading/sampling operations, various dusts (during supersacks and bag handling), and maintenance operations including the openings, clean-up projects, etc. 4 Written Hazcom and MSDS notebook, Respiratory, Hearing Conservation, Personal Protective Equipment and Chemical and Physical Agent Inventory were updated. 5. Training for Hazcom, Hearing Conservation, Radiation and Respiratory Protection has been completed. 6. Installed shelves in back of the lab hoods for bottle storage so that air flow to the baffle will not be restricted. 7. Completed the annual Chemical and Physical Inventory and included the maintenance job assignment. 8. Completed the SCBA competency test. RESTRICTED FOR USE WITHIN DOW 3 00 A 113888 confidential RECOMMENDATIONS 1. Develop a sampling strategy for the entire plant operation. Additional monitoring is needed for butadiene unloading/sampling operation, various dusts (during supersack and bag handling), and maintenance operations including line openings, clean-up projects, etc. (where potential contact with reactor solvents exists) and welding fumes. 2.. Fit test all personnel on the 3M-8710 dust respirator, the 3M easi-care and the Scott-Ovista. EVALUATION CRITERIA Industrial hygiene monitoring is performed to determine actual and potential exposure levels both as daily time-weighted averages (TWA) and peak or short-term excursion exposures. The results of personnel monitoring are compared with recommended exposure guidelines determined by Dow or independent agencies to be the most appropriate guidelines for a healthy work environment. The guidelines used are a test as stringent, and in many cases, more stringent, than the Occupational Safety and Health Administration ( OSHA ) permissible Exposure Levels( PEL'S ). The guidelines are developing using toxicology, epidemiology and industry experience. They represent airborne concentrations of substances to which nearly all employees may be repeatedly exposed throughout a working lifetime without adverse affects, the exposure guidelines for the chemical and physical agents monitored in 1992 at the Vector SBC plant are outlined below. Chemical or Phvsical Aaent Noise Cyclohexane Styrene Isoprene EXPOSURE GUIDELINES IVVA1 85 dB(A)4 300 50 NE Excursion^ Source3 90 dB(A) C4 Dow/ OSHA - ACGIH - ACGIH -- T.I.M.E. Dow Reaistrv Ref.5 DR-8000-1032 DR-0002-0097 DR-0103-1034 DR-0041-4517 1. TWA - 8-hour time weighted average exposure guideline. 2. Excursion - Short-term Exposure Guidelines C ceiling level which should not be exceeded at any time. RESTRICTED FOR USE WITHIN DOW 3. Source - Dow Industrial Hygiene Guideline ACGIH - American Conference Governmental Industrial Hygienist Threshold Limit Value (TLV) 4 OO A 113889 confidential OSHA - Permissible Exposure Limit Supplier Guideline recommended by the manufacturer. 4. See Noise Section (C - ceiling level which shlould not be exceeded at any time. 5. (T.I.M.E. is a Dow internal hazard data system in which information sheets are obtained covering Toxicology, Industrial Hygiene, Medical and Environmental elements). NOISE The current Dow exposure guideline for noise is a 90 dB(A) ceiling. In addition, the hearing Conservation Amendment document (29CFR1910.95) issued by the OSHA stated that the 8hour TWA noise exposures should not exceed 90 decibels as measured on the A-scale [dB(A)] of a sound pressure level meter at the slow response setting. A TWA exposure of 85 dB(A) or more requires participation in a hearing conservation program. Areas that exceed the 90 dBA ceiling are posted with signs and mandatory hearing protection is required, for simplification, a 100% dose is the maximnum allowable dose for the workday regardless if it is an 8 or 12-hour shift. TOXICOLOGICAL INFORMATION Toxicological data on the physical agents monitored in the Vector SBC Plant in 1992 are available in the T.I.M.E. system. SAMPLING AND ANALYTICAL METHODS NOISE Personal noise exposure measurements were taken using Quest M*15 audio dosimeter, ( Serial number EV 11030014) and Quest M-27, (serial number GW 1120008 ). set at 80 dB(A) threshold, 90dBA(A) criterion, and a 5dB(A) doubling rate. Instruments were calibrated before and after each survey with a Quest CA-12B calibrator, (serial number U8120999). VENTILATION Laboratory hoods were assessed using smoke tubes and an Alnor Model 8525 Thermo Anemometer velocity meter to determine capture performance and hood face velocities. AIRBORNE CHEMICALS RESTRICTED FOR USE WITHIN DOW 5 DO A 113890 CONFIDENTIAL Cyclohexane, styrene and isoprene airborne vapors were collected on 3M 3500 organic vapor passive dosimeter badges while being worn in the employee's breathing zone. Analytical analysis was done using a carbon disulfide extraction followed by injection into a FID gas chromatograph. Analyst was L. Almo, Environmental Service Lab and results reported under reference number 1387 and 1388. RESULTS AND DISCUSSION Personal noise monitoring results for employees in the Vector SBC plant are reported individually in Table 1. Operations personnel work a 12-hour shift and the sampling data was corrected to reflect the percent dose for the full shift. Sampling was conducted under normal working and plant conditions. Greatest potential exposure comes from routine work performed in the material handling area. The results represent potential rather than actual exposure because hearing protection is worn whenever entering a high noise area. The date of the last personnel noise survey was September, 1992. The survey included both area noise survey and personnel monitoring. There was one employee that experienced a Standard Threshold Shift. The results indicated a shift of 9 decibels in the right ear. A follow-up audiogram conducted in May, 1993 revealed that no additional loss has resulted since May, 1992. Personal samples were taken during normal work and plant operation. Samples were collected during the normal 12 hour shift and all classifications worked more than 8 hours. The sampling results as shown in Table 2 indicate that the cyclohexane concentrations were less than 1 ppm for the job classification monitored. There were no detectable amounts for styrene and isoprene. The results for cyclohexane are well within the exposure guidelines of 300 ppm; 50 ppm 8-hour TWA for cyclohexane and styrene respectively. There is no established exposure guideline for isoprene. RESTRICTED FOR USE WITHIN DOW 6 DO A 113891 Confid^^ttal table 1: Results of Employee's Personal Time Weighted Average Noise Exposure1 at Vector SBC Plant, Louisiana Division, Plaquemine , Louisiana during 1992. Master Number Job Assian. Date Sample Time fmin.1 Avg. Sound Level dBfA) %<3) Dose % Dose Corrected To 12-Hr. Shift Comments^ 433809 433809 439-02-3921 436-31-8439 439-51-5741 434-98-8361 432902 433-37-6041 435-29-9712 Op. Spec. 16-Apr Op. Spec. 06-Sep Saf. Tech. 16-Apr Saf. Tech. 02-Jul Saf. Tech. 02-Jul Lab Tech. 06-Aug Shift Supr. 16-Apr Wh'se Op. 23-Apr Wh'se Op. 23-Apr 614 569 575 493 490 573 572 461 576 76.9 16 82.6 35 74.0 11 73.6 10 73.2 10 72.2 8 74.4 11 75.1 13 82.7 36 19 45 14 15 15 10 14 20 48 Train 1- Normal duties. Unplugging Lines in the material handling area. Routine duties. Routine - Forklift Observer- Material Handling Sampled hoppers 8 times Made 4 rounds in plant. Driving Forklift Repackaging process. Industrial Hygiene Exposure Guidelines: OSHA 8-Hour TWA OSHA 12-Hour TWA PEL Dow 90 dB(A) Ceiling (2) 90dB(A) 87dB(A) 100 1...Monitoring conducted with Micro-15 Noise Dosimeter and Micro-27 Noise Logging Dosimeter - each set at 80 dB(A) threshold, 90 dB(A) criterion level and 5 dB(A) doubling rate and calibrated before and after each survey with a Quest CA-12B calibrator. 2 Exposure should not exceed the ceiling limit at anytime unless hearing protection is worn. Hearing protection was worn in the posted areas where noise levels are greater than the ceiling limit of 90dB(A) as part of the normal job routine. 3 Percent dose expressed acordingto the Louisiana Division 85dB(A) TWA would be twice that shown in Table 1. RESTRICTED FOR USE WITHIN DOW 7 DO A n3892 CONFIDENT TAt Table 2:-- Results of Employees' Time-Weighted Average (TWA) Exposure to Cyclohexane, Styrene and Isoprene at the Louisiana Division Vectoi SBC Plant, Plaquemine, Louisiana, During 1992. Master No. Time JobAssion. Date /Min.L Concentration, ppm(v/v) Cvclohexane Stvrene Isoorene Comments 287351 438-04-7819 Dowell Dowell 3/10 425 3/10 485 < 0.031 0.03 <0.041 ND (0.03)2 < 0.031 ND(0.03)2 Vacuum Al beds from column. Wore Comfo IIOVAG half-face respirator. 242689 Op. Spec. 3/12 485 0.04 ND (0.03)2 - Commission line on D-210. 433809 Op. Spec. 3/12 468 0.05 < 0.031 - Issued Permits 439-51-5741 Safe. Obser. 3/12 465 0.07 0.05 < 0.031 Unloaded isoprene railcar. Routine duties. 436-17-3211 Instru. Tech. 3/12 470 0.03 < 0.031 - Instrument work 439-08-5215 Instru. Tech.. 3/12 470 0.03 <0.03 - Instrument work 438-13-9373 Millwright 3/12 460 0.29 < 0.031 - Routine Duties Industrial Hygiene Exposure Guideline ACGIH TLV 8 Hr. TWA 300 50 NE Samples collected on 3M 3500 Passive Dosimeters 1. BLQ Detectable amount but below the analytical limit of quantitation for the survey sampling conditions. 2. ND - None detected with the analytical limit of quantitation noted in parenthesis. RESTRICTED FOR USE WITHIN DOW 8 DO A 113093 CONFIDENTIAL JOB DESCRIPTIONS VECTOR SBC PLANT - BLOCK 43 SUPERINTENDENT Responsible for managing the overall business of the plant. May be present in emergency situations, spill areas, etc. Assists in investigating problems in the process area. Spends 95% of the time in an office environment. PRODUCTION SUPERVISOR Responsible for managing the daily production of the products in the plant. Investigates problems in the process area. May be present in emergency situations, spill areas, etc. May be outside up to 15% of the time. SAFETY COORDINATOR Responsible for implementing and maintaining the safety programs for the entire plant. Writes plant permits, conducts on site inspections. Sometimes the person in this capacity may be responsible for safety observing ( approximately 2% of the time). He may spend 20% of the time in the process area. PRODUCTION ENGINEERS Manages a set of unit operations within the process plant. He coordinates plant improvement projects, installation and equipment start-ups. Coordinates production of material; investigates problems in the process areas. May be in the area 20% of the time. SENIOR QUALITY ASSURANCE SPECIALIST Responsible for directing the daily activities of other lab technicians. Assigns non-routine projects, calibrates and maintain lab equipment. Occasionally performs general lab analysis of process raw materials, finished products and waste water. QUALITY ASSURANCE SPECIALIST Performs quality control testing of raw materials, process samples and finished product. May handle samples that contain Cyclohexane, Styrene, Isoprene, Toluene, Methanol, Carbon Disulfide, etc. Approximately 85% of the time is spent in the laboratory performing analysis, calibration and methods development. QUALITY/LAB SUPERVISOR Responsible for the laboratory and the quality system in the plant. Spends 90% of the time in an office environment. SENIOR OPERATIONS SPECIALIST Responsible for 'running the board.* Rounds are made to check process equipment. Prepares additives, unloads raw materials such as cyclohexane, styrene, isoprene and butadiene. ENVIRONMENTAL SUPERVISOR Responsible for administering the Industrial Hygiene programs in the plant. Spends 50% of the time in an office environment. DO A 110894 CONFIDENTIAL. LISTED BELOW ARE JOB DESCRIPTIONS OF MAINTENANCE PERSONNEL WORKING IN THE VECTOR SBC PLANT BUT REPORTING TO A CENTRALIZED MAINTENANCE ORGANIZATION. MAINTENANCE FOREMAN Responsible for supervising and scheduling daily activities of maintenance personnel. Will spent approximately 50% of the time in the process area coordinating jobs. Exposure to chemicals is minimal. MILLWRIGHT Responsible for equipment and pump maintenance and repair. Will spend up to 50% of the time in the plant process areas with the remainder of the time spent in the shop area working on equipment. May be exposed to some residual chemicals remaining in the equipment. piPEeLTTER Responsible for maintenance on process line sin the plant. Can spend up to 50% of the time in the plant process areas with the remainder of the time in the shop area. May be exposed to some residual chemicals left in the process lines. INSTRUMENT TECHNICIAN Responsible for maintenance , calibration and installation of all instrumentation and critical devices. He may spend 75% of his time in the process area. Minimal exposure may result from residual chemicals left in the process lines. ELECTRICAL SPECIALIST Responsible for the maintenance, calibration and installation of electrical equipment in the plant. May spend 75% of the time in the process area. Minimal exposure may result from residual chemicals left in equipment that may need repair or working on equipment while the process is in operation. SAFETY TECHNICIAN Primarily responsible for safety observing. This person is also responsible for unloading raw materials such as butadiene, cyclohexane, styrene, isorpene. Also packages hazardous waste. Will spend up to 50% of time in the process area. 9/93 jobdes.doc 00 A 113f39S CONFIDENTTAL PROCESS DESCRIPTION VECTOR SBC BLOCK 43 To produce elastomers at the Vector Styrenic Block Copolymer Plant, isoprene, butadiene, styrene and a purified solvent are mixed, reacted, and separated. Solvent is recovered and sent back to the solvent feed. Vapors are recovered from the process and sent to the flare. The elastomer is pelletized, dried, blended, stored, packaged, and shipped. All the tanks and drums are nitrogen padded to prevent breathing losses. The plant is subject to the requirements of LAC 33:111.2121 to control fugitive emissions. Bag filters are installed on the hopper and all blowers to reduce particulate emissions. All process vents in the reaction area, solvent recovery area, and raw materials area shall vent to the flare. An Environmental and Industrial Program has been established. DO a confident TAl- Data collectad 9/22/92 Dosimeter Used - Quasi M-27 Modal#-GW 2060067 Calibration Bafora 109.8 Altar 109.7 12 Shift 1 loader figure l B-4352 Blender Area , Noise Monitoring Survey 104 103 I B641B 82S11A B600B B600C B600F B2610B N B1540C B1540B B1S40A B640B B640A B600A B600G B6000 B2610A V RESTRICTED FOR USE WITHIN DOW 9 DO A M 3897 COMF1DENTTAL V. figure 2 B-4352 Data collected 9/22/92 Packaging/Storage Building Noise Monitoring Survey N 10 A 113898 CONFIDENTIAL ATR/Sm(^COHnUT10M Block: 43 Plant: Vector SBC VKCTOK SMC rm SIS niKKIISTUY s-s- ... s--I--l + STYUKNF STYKKNK + sill. (CY(-U)/ISOI*) J r-- IlUiANOX i TNIM* s s - s -- + ISOl'UKNK "I.IVK" SIS + 11* A "NKIITKAI.r/KI*" + SIS ------ "TKKUINATKir 1*A + SIS -- 'STAUIUZK1V ------- SIS HKVOMTIZATION ,l^:l.ucTlZKlr, I final PKomicr - SIS + TAM* --1 SIS (CYCLO/ISOI*) MAC./M, 7-00 DO A 113099 CONFIDENTIAL STYRENIC BLOCK COPOLYMER FLOW SHEET L/ CONFIDENTIAL. O