Document ZnvmLMR84GX0YeK0GzDnmO7q8

Intra-Company Communication CONFIDENTIAL Mr. V. A. Jones, Manager Industrial Relations Department Engineering and Research 8taff cc E. A. Irvin, M.D. R. T. Ross May 26, 196l Re: Periodic Industrial Hygiene Survey - Engineering and Research Staff On May 11, 1961, an industrial hygiene survey vas completed by Mr. R. Anderson. Ventilation, paint thinner vapors, chlorine gas, stray radiation, illumination, noise levels, carbon monoxide and mercury vapors were sampled. Also, cafeteria and sanitary facilities were observed. The results are listed on the attached data sheets. Summary and Recommendations 1. Ventilation: With few exceptions, hood face velocities in the Scientific Laboratories and Research Building were considerably below the recommen dations of the Michigan Department of Health. Air velocities through the open door areas of the hoods should be increased. Convenient length asbestos or chain curtains would give a necessary increase in pickup air velocities under canopies in the rooms listed in the discussion, In the Maintenance Building Woodworking Shop, ventilation should be increased on the Delta saw and extended to include the disc Bander. 2. Chemicals: In-laboratory handling of chemicals appears satisfactory. However, safe use and storage of many highly toxic chemicals requires adequate ventilation in the hoods and in the storage space under the hoods. Efforts to find substitutes for benzene and carbon tetrachloride in the present control tests should be continued. ^ ~---- 3. Paint and Solvent. Vapors: The present condition is satisfactory. No recommendations. 4. Chlorine Gas: Since chlorine gas concentrations are excessive at the operator during aluminum treatment, enlarging of the canopy, without interfering with the operation, plus increased exhaust velocity is needed. 5. Stray Radiation: The present conditions are satisfactory. O PRODUCED BY FORD Mr. W. A. Jones -2- May 26, 1961 6. Illumination: Illumination at various locations throughout the Research and Engineering area vas checked. Two locations vith inadequate light ing are noted in the discussion. Local plant engineering should review and make specific recommendations for correction. 7 Noise Levels: Because of occasional excessive noise exposure, the operator in cell D 8 of the Dynamometer Building and the planer operator in the Maintenance Building Wood Shop should wear ear plugs or muffs when within two feet of the operating machines. 8. Carbon Monoxide: Exhaust control and air-borne carbon monoxide concen tration were satisfactory in the test cells and garages throughout the area." 9- Trichlorethylene Vapors; At all degreasers concentrations were within the maximum allowable limit. 10. Mercury Vapors: Results were well below the accepted maximum. 11. Cafeterias: Warning lights or exteriorly mounted thermometers which are constantly checked by plant protection should be installed on the kitchen and branch cafeteria food refrigerators where not already in stalled. 12. Sanitary Facilities: With the exception of chipped paint and plaster in the womens' rest room of the Vehicle Experimental Garage, house keeping and maintenance in the hourly personnel rest rooms were good. In the Maintenance Building flat top lockers were found with an open space between the lockers and the floor. Both of these conditions make an efficient clean-up program difficult. 13. Miscellaneous Items: The amount of air-borne carbon disulfide vapor created by the spray application of Stresscoat in the Body Engineering Building and the berrylium oxide resulting from a foundry operation were not sampled as these operations were not performed during the survey. It iB recommended that plant personnel be contacted and ar rangements be made so that this 8ection can evaluate the air-borne concentrations of these two materials. This office would appreciate hearing within 30 days through regular channels what action is contemplated on items listed above as 1, 2, 4, 6, 7> H> 12 and 13- Attachment J. C. Radcliffe, Supervisor Industrial Safety Section 007 0??4 PRODUCED BY FORD Mr. V. A. Jones - 3- May 26, 1961 Discussion Ventilation; Hoods - The Michigan Department of Health recommends face velocities of 100 fpm (linear feet of air per minute) through the open door areas of hoods handling chemicals and moderately toxic materials and 125 to 200 fpm for highly toxic or radioactive material handling hoods. Two of the radioactive materials hoods and one bench top chemical exhausting hood met these requirements but the other hoods in the Scientific Laboratories and Research Building were below these minimum velocities. The measured face velocities are listed in the attached data sheets. Hood exhaust velocities should be increased. Since conservation of conditioned air is a problem, consideration, other than keeping hood doors closed when not in use, might be given to replacing some hoods with flexible "spot" exhaust venti lation with provision for positioning or to converting from horizontal to vertical sliding hood doors thus allowing adjustment to the minimum open face vidth needed by the man using the hood. Canopies--In the middle bay metallurgy department, the canopy does not adequately control chlorine vapors from the experimental aluminum treatment. Correction . through enlarging the canopy and increasing the exhaust velocity is necessary. Pick up velocities at the source of dusts, vapors and gases were inadequately low under canopies in rooms 8 3075, 6 3020, S 3006, 8 3006 Bolder room and 8 20^5 of the Scientific Laboratories and Research Building and in the Maintenance Building Metal Working Shop soldering area. Convenient length asbestos or chain curtains would increase these pick up velocities. Maintenance Building Ventilation--The slot velocity on the Woodworking Shop's Delta Bav was zero and the disc sender was not ventilated. Ventilation should be increased and extended in this shop. Chemicals: In-laboratory handling of chemicals appeared satisfactory. However, highly toxic materials such as bromine, fluorine, hydrofluoric acid, thionyl chloride and hydrazine are stored in hoods or in the storage space under the hoods where there is little or no ventilation. Efforts to find substitutes for benzene and carbon tetrachloride in the present control tests should be continued. Paint and Solvent Vapors: The present condition i6 satisfactory. Chlorine Gas: At the operator, chlorine gas concentrations were seven times the maximum allowable limit during experimental aluminum treatment. Enlarging the canopy without interfering with the operation plus increased exhaust velocity is needed. . Stray Radiation: Stray radiation was within acceptable limite at the radioactive material laboratory hoods, the X-ray diffraction units, the hospital X-ray operator's booth and the new Gammacell. Wipe-tests for radioactive material at the hood control knobs and bench top in the hot lab were negative. S007 C 9 25 PRODUCED BY FORD Mr. W. A. Jones -k- May 26, 1961 Illumination: Illumination vae checked at various locations throughout the Research and Engineering Staff area. Special attention was given to the Body Engineering Building vhere inadequate illumination is alleged. Supplemental ~ lighting is suggested at the visicorder and control panel in'the brake teat room of the Scientific Laboratories and Research Building, on the metal working shop table in the Maintenance Building and in areas of the Body Engineering Building where vernier scales must be read. Hoise Levels: We understand that ear defenders are available to employes work ing near te6t engines and compressors. Because of the high noise level, the oper ator in cell D 8 of the Dynamometer Building should be especially conscientious in this respect while working within two feet of the operating six cylinder truck engine. Another location where ear defenders should be worn during occa sional excessive noise exposure is at the wood shop planer in the Maintenance Building. Slightly excessive constant background noise in the hospital audio metric room can be brought within the ASA standard by plugging or removing the louvers from the incoming air duct. Carbon Monoxide: Exhaust control and air-borne carbon monoxide concentrations were satisfactory in the test cells and garages throughout the area. Trlchlorethylene Vapors: At all degreaserB concentrations were within the maxi mum allowable limit of 100 ppm. Mercury Vapors: At manometers and the mercury fusion pump results were well below the accepted maximum of 0.1 mg/m3. Cafeterias: General conditions in the cafeteria kitchen were good. However, there were no warning light systems or easily visible thermometer to warn of power failure in the kitchen and branch cafeteria food refrigerators. Warning lights or exterior mounted thermometers which are constantly checked by plant protection should be installed. Sanitary Facilities: Sanitary facilities in shop areas rather than office and engineering areas were inspected during this survey. With the exception of chipped paint and plaster in the womens' rest room of the Vehicle Experimental Garage, housekeeping and maintenance were good to excellent. The old type flat top lockers found in the Maintenance Building are difficult to keep clean and lockers obtained in the future should have slanted tops. Open spaces between the lockers and the floor should be enclosed with sheet metal so as to eliminate the possibility of debris accumulating under the lockere. Miscellaneous Items: Carbon disulfide is a highly toxic material which requires good local exhaust. At the present time thiB operation is performed in an exhaust ventilation room which normally does not provide sufficient control for use of material of this type. Better control would be provided by performing this operation in an exhaust ventilated booth. The present exhaust ventilation present in the foundry operation is questionable for adequate control of berryIlium oxide. PRODUCED BY FORD Mr. W. A. Jones -5- May 26, 1961 These operations were not performed during the survey, therefore, evaluation of the quantity of air-borne contamination was not obtained. Because of the physiological effects that may result from exposure to these two materials, this Section would appreciate an arrangement for these operations to be sampled. 5007 017 ' PRODUCED by ford Ventilation Data Sheet #1 Engineering and Research Staff location Face Air Velocity, PPM Chemical & Physics Lab Hoods, Scientific Labs & Research B11oom 8 1 3062, II ft hood 11 M - northeast " southwest corner 1st hood " 2nd hood " Ri oom S 11 Room 8 It 30It 68, It 3(01 70, ho11 od II It It - east west east vest side side, side Bide lab. " door " open closed Room 8 3072, II vest side II 11 Room 8 3074 It east side east side II II II It It 11 It It it it 11 vest side (glass booth) open V " almost closed storage space under east hood RIt oom 11 It 6 3011 79, 11 It hoII od. II small. southwest corner, 1st hood " " 2nd hood " " 3rd hood hood.on bench top, weBt side II II II " " " " east side R11 oom S II 3011 75, It courtyard anteroom hood main lab hood (nitric oxide, sulfur dioxide) main lab hood, storage area under hood canopy hood, center of lab. Room S 3071, hood, ea6t side (thionyl chloride and It It trichloroethyl chloride) " west side R11 oom 8 301169 " " Room 6 3061, 11 east side vest side Room 8 3049, hood . Room 8 3044, north wall hood, radioactive material Room S 3044, hot lab hood, radioactive material " " hood, room adjacent to hot lab. Room 8 3028, physics lab hood Room 8 3028, potassium fluoride oven exhaust Room 8 3020, canopy hood Room 8 3006, canopy "" " , inside small spray booth " " " in adjacent room (silver solder) Room 8 2071, hood, annex Room 8 2059# hood Room 8 2045, canopy, (graphite dust and heat) It II ft It II II It Room 8 2037, Resource lab (should have hood facilities available for venting oxides of nitrogen. ) 52 60 69 10-22 50 48 48 24 62 60-76 52 170 0 95 0 (Hh2gF^Btorage area) 38 29 32 96 112 70 35 0 0 20 60 30' 50 85 55 48 52 50 70 450 65 40 (l ft. above bench) 0-10 0- 5 (l ft. above bench) 60 ^5 0- 5 (a*, source) 35 (at face) 6007 092S PRODUCED BY FORD Ventilation (continued) Data Sheet #2 Engineering and Research Staff Location Face Air Velocity, FPM Room 8 2030, Metallography lab. hood 15 (face vel.) 300 (slot vel.) " " Etching lab hood (uBe hydrofluoric acid) 12 Room S 2010, canopy with chain curtain " " canopy ventilated area - center of room 65 70 Carbide tip dumping, hood " " " room floor sweep exhaust 75 450-600 Room 8 2003, Experimental electrostatic spray booth 0- 45 " " 2 hoods 0 Room 8 2023, radioactive materials hood, large " "" " " small 125 125 Room 8 2031, nonmetallic materials 6- 12 " " naturaldraft-cold, Lindberg furnace 0 Room 8 1000, flexible exhaust duct, welding 280-350 Scientific lab & research, )j*23 blue print machine 40 " " " material devel. surface grinder 200 " " " material devel. cutoff machine 40 " " " material devel. drill press 450 " " " material devel. lathe 400 " " " material devel. belt sander 300 " " " material devel. bearing lab, canopy 0- 5 " " " Metallurgy Dept., middle bay, chlorine gas canopy exhaust, at face 350 at chlorine source 0- 25 RIt oom E 11 31tl 97, tt hotl od. 11 next to door, southwest 2nd from door, " northwest 6ide cofrt ner Rtl oom E tt ft 11 3t1l 91, 11 tt tt Ltul brication tl It It LIat b., tt It It 1st hood, 2nd hood. 1st hood, 2nd hood. 3rd hood, southwest southwest northwest northwest northwest side side side side Bide Room E 2152, hood. north side 5 2-3 95 60 90 90 65 2- 5 0 Room E 2156, hood over scale Room E 2156, paint hood Room E 1155, hood. stress coat test with CS2 100-1000 88 130 Room E 2205, booth Room E 2205, heat treat furnace canopy l4o 100 Maintenance Building Paint shop Metal working shop, solder area canopy "" " " " fume source "" " flexible dust Woodworking 6hop, planer " " disc sander " " Delta saw 250 250 0 100-1000 200-900 (slat) no ventilation 0 (slot) iOO? 0929 ' PRODUCED BY FORD Ventilation (continued) Data Sheet #3 Engineering and Research Staff Location Face Air Velocity, PPM Body Engineering #1 paint booth, at sprayer #2 paint booth, at sprayer jj*3 paint booth, at sprayer Engine Experimental Garage Booth, B.T.# PU71803 Booth, B.T.# PU71802 Booth, B.T.# P47l8o4 * Booth, Jet flow test with benzene Ford Vehicle Experimental Garage Floor exhaust, main aisle Monoxivents Southwest wheel aligning pit Lincoln Continental Vehicle Experimental Garage Wheel aligning pits ' Monoxivents Engine Experimental Garage Building, Visualiner pit Wind Tunnel Garage, pit Vehicles Test Building South end grease pit Front end pit Research Vehicles Laboratory Garage Visualiner pit Garage monoxivents Engine and Electrical Building, north crib ozalid machines Power House, re6t room - poor exhauBt, approx. 4" x 6" opening Paint Shed, ammonia filling station booth Body Engineering Building Metal shop welding booth Plastic fabricating area, sanding booth n tl t tt ti " " " sanding machine Epoxy booth in wood shop Shaper room, at shaper exhaust 100-300 75-250 100-400 125-225 175-250 200-250 0- 25 at source of vapors 600 1000 (slot) 1000 1000 1000 (slot) 1000 1000 1000 No exhaust 1000 1000 (slot) 150 75 75 (at vapor source) 1000 at 4" from duct 100-125 350 (slot) 1000 1000 1000 *FFM meanB linear feet of air movement per minute at the base of hoods, booths or canopies. Exceptions are noted in parenthesis. sonw'? * W * ' PRODUCED BY FORD Paint and Solvent Vapors Data Sheet #4 Engineering and Research Staff Location Concentrations, PPM* Scientific labs and Research, cell 13 dynamometer test Maintenance Building, paint shop, in booth Body Engineering, paint shop, #2 booth Engine Experimental Garage, benzene Jet flow test "" " carburetor test room #1 Faint Shed, general area 100-1*50 (gasoline spillage) 0- 50 0 0-100 (momentarily) 0-150 0- 20 PPM means parts of paint thinner or solvent vapors per million parts of air. The maximum allowable amounts for an eight hour exposure is 200 ppm for xylene vapors and 25 ppm for benzene. Chlorine Gas Location Results, PPM* Scientific Labs and Research, middle bay metallurgy dept: During aluminum melt treatment and pouring Five to fifteen minutes after pouring 7.0 0.0 PPM means parts of chlorine gas per million parts of air. The maximum allowable exposure is 1.0 ppm. Stray Radiation Location Stray X-radlation, Mr/Hr* Scientific Labs and Research Room 3044, hot lab hood " " " " storage vault " " radioactive materials hood Room 1026, 5 KV Norelco X-ray diffraction " " , 45 KV Horeleo X-ray diffraction tt tt it ti ti n tt Room 3049, G.E. 40 KV XRD4 X-ray diffraction " " Phillips X-ray diffraction Hospital X-ray unit, chest X-ray (in booth) " "" " (outside door) " " " lumbar spine " " " foot X-ray Room 8 2023, radioactive waste, in barrels Room 8 1076, gamma cell, 2" from front "" " " 2" from rear and sides "" " " at drawer with collar open "" " " 3* from cell 0 0-2.5 0 0 1.5-20 (2" from source) 0.5 (no shield) 0 (with shield) 0.1 0.1 0.1 0.1 0 0.1 0 2.5 1 4 0-1 Mr/Hr means miHiroentgens of stray x-radlation per hour. 6007 C531 PRODUCED BY FORD Radioactive Source Lab Wipe-Tests Data Sheet #5 Engineering and Research Staff location Radiation In CPM* Scientific labs and Research Rit oom II M ft It It 3041 4, M II M It ft h1o1 t If tt It test " " " " main lab tt " lab, hood control " Inside hood " table top " at vaults " hood window hood window inside hood knobs 0 0 0 0 0 0 0 *CPM means counts per minute above the background count of 50 cpm on our Tracerlab laboratory monitor. Illumination Scientific Labs end Research Middle bay, metallurgy Room E 3197, Fisher isotherm controls Room E 1155, at desk _ Brake dynamometer roonf, Visicorder Brake dynamometer room, at brake test Brake dynamometer room, at control panel Reading in Foot-Candles 35-50 30-35 30-35 28 30 12-15 Dynamometer Building, Mr..Patterson's office, at desk " " " ... " secretary's desk " " dynamometer test engineering desks " " Mr. Gass' office, at desk " " Mr. Rhode's office, at desk " " Operations office, central desk Maintenance Building, paint shop, inside paint booth " " metal working shop, solder table " " metal working shop, bench top Ford Vehicle Experimental Garage, general area "" " " Visualiner pit without supplementary lighting Lincoln Continental Experimental Oarage,Visualiner pit without supplemental lighting Lincoln Continental Experimental Garage, general area Engine Experimental Garage Building, Visualiner pit, without supplemental lighting Wind Tunnel Garage, pits without supplemental lighting Vehicles Test Building, grease pit Vehicles Test Building, front end pit Vehicles Test Building, general area Research Vehicles Laboratory, garage ViBualiner pit 30-35 28-32 70 30 28-50 38 45 8-10 50 20-40 5-10 5-10 20-40 8 5-10 5-10 5-10 20-40 5-10 6007 0932 ' PRODUCED BY FORD Illumination (continued) Iteta Sheet #6 Engineering and Research Staff Location Reading In Foot-Candles Body Engineering Metal shop men's rest room Metal shop locker roam Wood shop men's rest room Vibration test equipment meter, bay S 29 s 23 0 27 Reliance control panel K 36 prototype assembly H 36 ' G 36 H 33> reading fine vernier scale . H 27, working inside car body H 25, body build up K 23, hood and fender build up F 21, bench 14 B F 22, bench 12 B F 22, bench 11 B F 23, bench A 3 F 25, bench 7 B F 25, layout table F 27, bench B 1 F 28, bench area F 27, checking table Machine shop, at table " " at lathe " " #1 shaper " " #2 shaper " " milling machine " " surface grinder C 25, bench 4 C C 25 C 24, bench 6 C C 24, bench 7 C C 24, bench 8 C C 23> bench 4 A C 21, bench 13 C C 21, bench 14 C Metal shop, Kirksite welding booth Paint shop, general area Plastic fabricating sanding booth 35 30 15-20 35-45 J+5 50 J*5 62 40-42 42 2 20-45 30-40 65 90 90 65-80 90 50-80 90 5-70 60 85 350 (supplemental lighting) 55-60 35-70 50-300 55 85 70-75 80 85 65 90 90 85 40-60 60-85 10-20 Engine and Electrical Engineering Building, n. blue print crib Power Bouse, general area "" control panel "" rest room Paint Shed 70 10-120 10-15 15 10-120 E 007 0973 ' PRODUCED BY FORD Noise Levels Data Sheet #7 Engineering and Research Staff Location Frequencies in Cycles per Second Over- 20 75 150 300 600 1200 2400 4800 all 75 150 300 600 1200 2400 4800 96U0 Scientific Labs & Research Cell #3, dynamometer room Ceil #5, " " Cell 12 B, " *" Cell 12 A, " " Cell 10 A, " " 86-90 90-94 83 84 78-83 Dynamometer Building Cell 16 C, dynamometer room 89(at control panel) Cell 16 C, " " 94-96(lft.from engine) Components room, air conditioning compressor 90-92(intermittently) 11 11 n 100 (momentarlly) Cell 19 74(at control panel) Cell 19 Cell D 8 at operator 93-97(2ft. from engines) 94-96 75 77 90 88 Cell D 8 at engine Cell D 13, cardinal 104 88 82 79 22 22 Hospital audiometric room Hospital audiometric room vith air duct louvers removed: Maintenance Building . Paint shop booth Metal shop grinding Wood shop, planer 60 59 59 58 98 89 80-100 95-108 89 49 47 93 97 Power House, near compressors 104 Ford Tentative Goal ASA Standard no 102 40 40 39 43 38 38 86 93 90- 9828 108 96 94 40 4o 92 26 35 31 87 98106 94 47 90 2 31 27 85 98106 94 57 85 24 24 22 80 91 94 62 81 90 19 17 74 80 94 67 Note: All noise levels are in decibels 600'' 0934 PRODUCED BY FORD Carbon Monoxide Data Sheet #6 Engineering and Research Staff location Scientific Labs and Research Middle bay metallurgy department Dynamometer cell #3 Dynamometer cell #5 Dynamometer Building Dynamometer cell #l6c Dynamometer cell #19D Dynamometer cell f(*8 D Lincoln Continental Vehicles Experimental Garage Scientific Labs and Research, Room S 010 Screen room Starter test room Transportation garage va6hmobile Wind tunnel garage Vehicles 3te6t Building Results, PPM* 0-25 Less than 10 Less than 10 Less than 10 Less than 10 Less than 10 20 Less than 10 Less than 10 Less than 10 Less than 10 Less than 10 Less than 10 PPM means parts of carbon monoxide per million parts of air. The maximum allowable limit is 100 ppm for a daily eight hour exposure. Trichlorethylene Vapors Location Results, PPM* Scientific Labs and Research Bearing lab degreaser Garage, degreaser Garage, degreaser Garage, degreaser Ford Vehicle Experimental Garage, degreaser Vehicles Test Building, degreaser Experimental Engine machine 6hop, degreaser Experimental Engine inspection area, degreaser Body Engineering, paint shop degreaser Dynamometer Building, degreaser, La IT 0-20 150(momentarily) 25-80(on stand) 10(on floor) 5 50 25 25 5 5 *PPM means parts of trichlorethylene vapors per million parts of air. The maximum allowable concentration is 100 ppm for an eight hour day or 200 ppm for short exposure. Mercury Vapors Location Results, Mg/M^* Scientific Labs & Research Garage, manometer spillage Less than .02 Room 8 1026, Mercury Vacuum fusion Less than .02 *Mg/M3 means milligrams of mercury vapor per cubic meter of air. The maximum allowable limit is 0.1 Mg/fP. 1007 ''535 PRODUCED BY FORD