Document aDy9ko5jkJoQKj9jmGrXBm6DN
DIAMOND SHAMROCK PLASTICS CORPORATION Delaware City Plant
September 9, 1981
TO: FROM: SUBJECT: CC:
J. R. Semancik*
R. A. Barrish*
Delaware City Health and Environmental Report - August, 1981
Dr. R. McBurney
Messrs. E. Baier* J. A. Bailey
D. C. Bobish/J. E. Pyle/C. W. Greenberg/S. A. Kuhls B. Christensen
C. A. Burkins/P. L. Bowman
R. F. Cronin/W. D. Peeples
D. L. Lull
R. E. Nagy
S. W. Schaefer
File No. El*
(* with attachments)
I. Health
A. General
Airborne lead sampling was conducted in the Compound Plant on August 5 in conjunction with the OSHA inspection. Our values ranged from 136 to 1170/4g/m (PEL=50yig/m ) while OSHA's range was 90 to 12,000/fg/m^.
A follow-up study conducted 2% weeks after the termination of the lead run showed t^e operators exposed to 18-49y7 g/mJ and area samples of 7 to 20^4g/m . The background level of airborne lead is high and there is an excessive level of lead during a lead production run. Before the next run, engineering and work practice controls will be developed and implemented along with upgrading the respiratory protection program.
B. VCM
1. Personnel Exposure
a. A total of 12 TWA samples were analyzed during August. A copy of the results is attached. (Exhibit I)
VCM Range (PP0
<1 1-5 5-10 >10
Number of TWA
11 1 0 0
Number of Masks Worn
10 1 0 0
OCC 11468
Delaware City Health and Environmental Report - August, 1981
September 9, 1981 Page Two
1. Personnel Exposure (cont'd)
b. One ceiling sample was analyzed during August. The purpose of this test was to determine the necessity for respiratory equipment while sampling unstripped latex. A two minute sample resulted in an exposure of 6.38 ppm. This job function will be retested.
VCM Range (ppm)
Number of Ceiling
Number of Masks Worn
<10
1-5 1
5-10
0
>10 0
0 1 0 0
c. Personnel exposure by area is summarized below and in Exhibit II.
Month
Poly Area VCM (ppm)
Bio Plant Avg. VCM (ppm)
Reclaim
Incineratioi
& Unloading
Avg.
Avg. VCM (ppm) VCM (ppm)
Aug., 1981 July, 1981 June, 1981 May, 1981 April, 1981 March, 1981 Feb., 1981 Jan., 1981 Dec., 1980 Nov., 1980 Oct., 1980 Sept., 1980 Aug., 1980
0.31 0.35 0.83 1.35 1.57 2.37 1.30 3.47 1.36 2.82 3.71 1.30 0.60
0.10 0.10 0.10 0.10 0.44 0.27 0.10 0.18 0.10 0.10 0.10 0.10 0.10
0.48 0.14 0.47 0.12 0.42 0.44
0.93 1.07 0.22 0.31 1.24 0.36 0.36
0.14 0.10 0.13 0.11 0.20
0.26 0.12 0.21 0.10 0.1 1.18 0.1 0.1
2. Area Surveys
a. ARCAS area averages are summarized below and in Exhibit III.
Area
Average (ppm)
% <1.0 ppm
Polymerization #1 Suspension Polymerization Suspension Charge Suspension Drop Weigh Room
0.7 0.7 0.9 0.6 0.1
93.4 90.8 88.5 90.9 97.5
OCC 11469
Delaware City Health and Environmental Report - August, 1981
September 9, 1981 Page Three
2. Area Surveys (cont'd)
Area
Average (ppm)
% <1.0 '
Suspension Blowdown #2 Paste Polymerization #2 Paste Charge #2 Paste Drop #2 Paste Strip #2 Latex Transfer #3 Paste Polymerization #3 Paste Condensers #3 Paste Charge #3 Paste Drop #3 Paste Strip #3 Latex Transfer Reclaim Area Unloading Area Incineration Area Bio Dewatering Breathing Air
0.3 0.8 0.8 1.0 0.6 1.0 0.8 1.1 0.5 0.5 0.6 0.8 0.3 0.1 2.2 0.1 0.1
95.1 90.8 92.8 89.6 93.6 87.3 90.8 88.7 91.5 94.2 94.0 92.4 96.2 98.2 91.6 99.2 99.9
(Note: #2 Paste Plant is shut down. Readings are being observed to determine background levels).
b. Area readings for the control rooms are summarized below:
Area
Areas Average
% <1.0
TWA
Suspension A3 Paste Paste Dryer Reclaim
0.2 1.0* 0.2 0.1
94.6 98.7 99.1 97.0
0.10 0.10 0.14 0.10
* One excessive reading (2660 ppm), probably caused by cross contamination with another stream, resulted in an average of 1.0. The control room was <1.0 ppm 98.7% of the time.
C. Dust
Dust sampling was once again conducted in the paste bagging area. Results indicate that there is no problem. Dust sampling will be conducted quarterly in the paste bagging, suspension bagging, and compound blender floor areas. One of these areas will be sampled each month.
Results are included as Exhibit IV.
D. Noise
There were no noise surveys during August. The noise dosimeters were returned to the corporate group. A set of noise dosimeters were ordered and will be received during September. Further noise surveys will support the noise reduction program in the Compound Plant.
OCC 11470
Delaware City Health and Environmental Report - August, 1981
September 9, 1981 Page Four
E. Lead
The results of the lead testing were highlighted earlier in the report. The results are included as Exhibit V.
Engineering and work practice controls will be developed and implemented. The respiratory protection program will be upgraded and additional respiratory training will be conducted.
II. Environmental
A. Air
There still has been no action by the Federal EPA concerning our response on safety valve releases.
The monthly VCM data is summarized below:
1. Incinerators
1.22 ppm
2. Stripping
August
Year-to-Date
a. Latex
Number of batches stripped Average value (ppm) Batches out of compliance Excursions (24 hr. average)
312 1295
54 l
2136
986 272
10
b. Suspension
Slurry average (ppm)
35 30
Excursions (24 hr. average) 0 3
c. Wastewater
Monthly average (ppm) Excursions (24 hr. average)
1.5 2.7 08
3. Reactor Openings
a. Suspension Number of charges Number of openings Reactors sampled Samples exceeding compliance limit
1352 1352
21
1
11,118 11,118
189
22
OCC 11471
Delaware City Health and Environmental Report - August,
September 9, 1981 Page Five
1981
3. Reactor Openings (cont'd)
b. Paste Number of charges Number of openings Reactors sampled Samples exceeding compliance limit
4. Leak Detection
August
263 43 4
0
Year-to-Date
2112 643 41
5
Leaks detected Leaks repaired
5. EPA Reportable Releases
6. Total VCM Emissions
74 1005 82 813
02
a. Suspension Stripping Permitted pounds Actual pounds Over/(under) pounds
b. Paste Stripping Permitted pounds Actual pounds Over/(under) pounds
3094 271
(2823)
3359 2175 (1184)
26,029 1953
(24,076)
24,707 12,163 (12,544)
c. Reactor openings Permitted pounds Actual pounds Over/(under) pounds
d. Relief Valve Discharges Actual pounds
B. Solid Waste
189 67
(122)
1547 1107 (440)
2220
1. Monitoring of the on-site PVC landfill continues. Air readings continue to be below 0.10 ppm. Well water samples are being taken monthly.
The DSWA has tentatively approved the disposal of our waste treatment sludge and grits at the county landfill. A letter from DNREC stating that the wastes are non-hazardous is still required. This should be a formality as they have already stated that the wastes are non-hazardous.
OCC 11472
Delaware City Health and Environmental Report -
September 9, 1981 Page Six
August,
1981
C. Water
Sampling was conducted during the week of August 31. The purpose is to establish levels of pollutants for a separate NPDES permit for the Plastics Plant, and to establish base levels of "priority pollutants" which will be required for future permits.
III. Safety
Reactor Rescue Procedure Modifications
A block and tackle assembly was purchased and is being set up in the suspension poly room. More testing will be done to evaluate the block and tackle and our new procedure.
RAB:js Att.
R. A. Barrish
OCC 11473
%c " ^
)tbh(3i / JL_________ .............. --t
_ Dat de// SCa"smmpl1eA Year 'll NO.
f PERSONNEL)AND AREA CHARCOAL METHOD VCM ANALYSIS SHEETS
JToB-- - ,_ --"""nPdersdownnde1 l PumpI Iws
Pump Sample Operation Performed,Hu m n
P \ m m 1 a
d a a w ^ 4* > a n
Tn a J a *m a
Description
On Off Flow/1 No.
Type Area Monitored, etc.
VCMV TVi (PPM)
fHTa ea 1chnician Siqnature
V **f M4?P
Ci^O.Cj, /410 S Ci- to <nu TWA Sov??1' 1
-* -r o. 10 i tu
Y C t PMffR ir
Ml
AtScp <5? Amo Ross'
3t51P 'M'TLP J&53T
7? SJe^ : ' / iJ < : *// *7 W ' ,
X <ScV\ * a. /MCV -V . 'l/jS - ' ^
R- StWl ' '
3&S1T ?6&SP ,,2J., N.S,f
7? Pr_Ji/n-sJ,kt^j,' ' ' '~
/A- Surcic ` v; I -> C.
mo Ds'ioa Wso
1*150 /.4-5<S OJoo- ma o?oo IM5>0 TI^ W30 07$$ ms
S (, ?? Sg.n s 4<qa S'S , l! 58.ll 5 S. 11
6S-9t 55-tl
nm {vnft 1 ~fU l%3 <mq
i WA T1 VM
( WA
TvJ A TuA
TwA
TWA
tva
SuspThrwe S\JM?>w09F SvsfTli/^.oT' Utu-i HOT* VfKIt*- \ ^STF C-MRB&T'1,
Tm-reTr^O?-3 Ef>i.Qi?iX.
-* 0-2.^
V n-54 Tf o.qi
1
* 0 )A
1 jj
* <o-) 0 *. <0-10 :
1 v
-* ^ 0-10 ----------:---- ^------& -* 1.47
U57f ^ Fen. rtrt sUsg p ^R.Yarmeu
OSes ms '13/
5S.*fS 5MC
^n% Twa JViA
iMtiNt.HRIo'?
-H- O-VS oo4
1
Its IP "T 1 UcvjJEa
M Id Uto?
' 22 " ' F , W/WREU. '
0 3<n 'no SE-9H IDO *4 loot, o-tf
A174 Mwa in5* 2.
< o.l o u. 2-*~--i
(,Tu Nfi SnmruMfe 77-(.e>^w VtTifp1.^ L ^-7? OJ. ^ '
i. ' /'
- > / '':
' --
' oai-i """"" kH1
"
Exposure slip issued
^ Air mask worn. ' /_jl
CRT INPUT yIj I'l ; .'k l9ot T?! i !ALS
V
! Date/ Sample 1 Year'?! No.
8- 4
337A
30^6 A
` 8-U
^j4oA 3o4/A
8v 1 A 3yi
3Qif3 A
PERSONNEL AND (AREA/CHARCOAL METHOD VCM ANALYSIS SHEETS
Job
Personnel Pump Pump Sample Operation Performed,
Description
On Off Flow/1 No.
Type Area Monitored, etc.
VCM (PPM)
Technician Siqna ture
0800 l4T 02>OO H45
TlSi/
~7W} m TTw
yVoRT/w TTc Umiw.
SovtA
''
< O W& ------(-aZJ--JT--A-^-W^----------
10 '
O&OO Hns ms
Co.
TvA Wl4 TWI
Ast W^r
M
<0 .IG >0-10
t 4j'
IY I34c
2-IA
11m CtfLl WC, ifl3T mtnJCRn-ro'R VTACfi
;-za
W)
o^oo' /4?,0 5S.li
97a TwA
Pn^-nT?'Ttvr CsNaTR,"^.
<70,10
tiSOQ A*3 0 -68-Jl
976s TWA Ty-v Ca^rrrr*.
<0-10
3c>4fA
O^TO W3q OSlO IW3A OSIO
58.1/ 5S'iS . 6717
97^q 9774 9778
rwf\ TWA TWft
Vf/fcH 7*&c*\\ ^cctj^hA CaATf^oL ^Mirrs
TT <T"t7Pft k Cc N r?T
< 0,10 * 0,10
'! +
f'H
3047/1 30 *3 A
305^ d, 2>o5lA
Tn
305^ 30S4A 5 055 A 3>05VA
VT7 4
7os?A
S059A 3^4oA
0 Ct .... 0 h-1
^uni1
dYos OPJS
$112. l3i4 5S *f 9&s
Twa P>VSP>T'>RM* (Twr fcfA. < 0, )0
TW-^ 35>oT>(jUftbP>iN6 ScefcAiiS -1 0 la Ia3 .
0^10
S8.Sfe w Twa NoTi-rH TPVt LfivrfiU-
<0.10
\
0*10 ifM-5
8-8 97ta sm
Twa Twft
5coiW f^AC-r
< p. 10
< 0- | Q
1^5 54-J.i 9 m TwA VUsr
<0'io
CgOS 1415
54.CZ 97U Twa
Crf&trcK pmtAsVJ- }St?fffcTkr Tcs 0- 4o
o^oS 1415
5 5.4K
TWA
l\ 7 1*67
040 s 1415
5 4-4 9Tq T^A
TropTXck.
"
" T-ol 0.9 4
f
0405 1415
9m 77/A
" 7l~] 37 S
o?m |4l4b Cb 35
l7t Twa Mcitfj Tvttpfitfuu
^o-io
\
o-ioc H<+5
0^00
a^oc W5'0
52/3
5tT ^3 34
^7C3
9743 9773
TWA Twa Twa
So 1.1-'ll East V'ks-r
< o.io <0,10
<cmo
1 1.
VJ, T-ov-^
j
Exposure slip issued.
Air mask worn.
Date/ Sample Year 'S\ No.
3oOa So(,xf\
3oLsA
3064ft
PERSONNEL AND AREA)CHARCOAL METHOD VCM ANALYSIS SHEETS
Job
Personnel'"Pump Pump Sample Operation Performed,
Description
On Off Flow/1 NO.
Type Area Monitored, etc.
VCM (PPMl
05/0
47-JS.S .nu TWa (\/rtj?TW
LandA*-1-
**10
oSfO
59.
TJft
tva
<>, 10
05, T) lW sr?.
Twa fHT
<Oi 10
Slo i<H5
I77 ^ Tw f\ Vs-r
^n. i a
Technician Siqnature
V ill
)
o a " 1-* I-* J* cn
^Exposure slip issued.
^ Air mask worn.
/978
/?7f
/9XO
/fgi
LL**x 000
/97S
/f7?
mo
f<jp(
QufifLTEZL'f frvEflMcS fcti ?8Sonw5l VCM Sm?up$> CTivAj
OCC 11478
SMPLS 2754 2737 272? 2741 2740 2741 2735 2745 2734 273? 2734 2745 2733 273? 2725 2742 2835 2836 2830 2837 2833 2833 2840 2843 2816 283? 2828 2832 2838 2840 2842 2837 2815 280? 2818 280? 2821 2813 2811 2814 2811 2804 27?8 2801 2818 2815 2810 2819
NO > 1 147 104 76 147 209 184 70 21 209 102 83 27 184 177 489 164 27? 301 97 3? 501 288 154 734 332 481 154 24 260 422 266 4 25 117 36 161 112 238 297 40
OO
334 150 307 48 32 235 186
NO > 37 24 24 31 67 55 13 6 37 26 1? 10 60 59
152 29 52 40 12 7 99 47 17 159 71 63 27 7 43 71 45
1 9 50 16 94 4? 127 157 18 11 151 75 177
oo
15 198 93
A V 05 age: .3
1.
.4
^ li ui a o w ta ^
-!>o >o o j>co
ro t>io u u
m a u to co \ i 9
h m n o f u u a w r-j^ ' C
HIGH 280.0 71.6 124.0 123,0 121,0 110,0 27,4
11,0 102.0 74.4 31.3 28,1 190.0 147.0 513.0 55,3 82,4 1040,0 82.0 42.4 1000.0 146,0 20.0 1020.0 388.0 3000.0 208,0 20.0 584.0 884,0 104.0 280,0 416.0 27.6 2660.0 154,0 99.0 98.4 33.2 89.4 244,0 786.0 782.0 538,0 782.0 638,0 1900.0 42,8
18106 14 *.39 3 *.27 14 *,37 9 Ml 15109 15126 14:13 11:32 15! 57 5!10 9M3 14*18 12*40 1M9 8:46 15:52 16! 02 16:03 7 .*32 19 M3 12M3 16 ! 04 13:22
16:00
16:01
is: .12 21158 16! 55 20:i5 17:36 23M7
9:55
19126 9:58 9 M2 10:00 ?: 44 4:5? 9M6 22.* 17 9 MS 14J24 14`,25 9 *,51 9:36 9 *.53 20*,59
8/25 8/22 8/02 8/06 8/08 (3/03 8/08 8/25 8/18 8/1? 8/05 8/11 8/25 8/05 8/1? 8/07 8/19 8/10 8/10 8/20 8/11 8/03 8/13 8/10 8/19 8/19 8/10 e/.o 8/04 8/10 8/11 8/10 8/22 8/30 8/22 8/22 8/22 8/22 (3/18 8/22 8/20 8/22 8/M 8/14 8/22 8/22 8/22 8/01
SUSP CHARGE 1 PASTE CHARGE 1 VCM UNLOAD COMP RECLAIM COMP SUSP DROP 5 SUEC0 SCREEN WEIGH ROOM RAIL UNLOAD susp charge: 3 PASTE DROP 1 RECLAIM CUNT RM TRUCK UNLOAD A SUSP DROP 1 LATEX TRANSFER SUSP CHARGE 5 SUSP VAC COMP SUSP DROP 2 PASTE CHARGE 2 VCM CHARGE PUMP RECLAIM DECANT SUSP CHARGE 4 PASTE BLEND TKS POLY CONTROL RM EAST GASHOLDER SUSP DROP 4 PASTE DROP 2 HRC RUMP HOUSE TRUCK UNLOAD B SUSP CHARGE 2 PASTE BL.WDN TKS SUSP DROP 3 BREATH AIR SYS paste: dry cont ras te VAC PUMPS PASTE POLY CTRL. e:xpan drop deck OG BLOWDOWN TK 7M RE: AC Cl tG DCK E-'XP CONDENSER S UTIL PL.DO ROOF' BIO DEWATERING EXP CONDENSER N EXP STRIP 2F"L W EXP STRIP 1FL BREA AIR INTAKE BREA AIR PIPE INCIN AREA EXP STRIP 2FL E
/W 7(ExM&iT
* __
6*^10 >7* ji
*
LOG SHEET
o
Name
F.?efRTfc "~R. "R'bNo
Date
9-ii" S* 10.- Si
5-\l-l\
Pump#
3W
Time On/Off
OlOO MOO n
oil 5 ms
Respirable Dust
Nuisance Dust
Exposure (ms/m^)Exposure (mg/m3)ProductComments
M3
3.0^
&6 , T3piste 7X4
0.34
4. LX
"""Paste "1 2. 4
o-is
lo.40
?^7U ' ^6+STfrt v
>
OCC 11479
7*141/3/7 V
LOG SHEET
NAME
DATE
PUMP 0
XT5 wkch
8-5-S1 3394
3?m7 Coyrpir^o 8-5-TSI
7 54w ihSs 2f'5'3i 33^ 4
MATERIAL BEING RUN
JOB FUNCTION
FLOW RATE
wg-
WE"
f~loOR
Flexnc
'Etf'N&rR I'loffi;
.s
15
1.5
V'53fp 'S>izritn\lri-Q6H
M.
TIME ON OFF
tHSS J04O
oiS5 /040
loHS HZo
MS mg
DUST MASK WORN
ANALYTICAL
RESULTS aVm'TWA *V*5 75>b "fSb Pb Sb
COMMENTS
.2.5 5 o^jT
TpAmLL ct '*1'
39i JWQ^jJYQ i?.H I %
OSS
x
0^5
35 JJ34 ,>Hog
o o o
l-l 00 o