Document bBnwO44BRvoyMaBEOwV29mrZ

A CALVERT CITY PLANT INTEROFFICE MEMORANDUM To: H. Ortega From: B. D. Helms PVC Hygiene Program Date: 23 June 1983 Copies: G. N. Boyd E. K. McIntyre The hygiene program for the PVC plant should be updated in order to be used during your training programs prior to start-up. Status of the last review is attached. Please indicate which chemicals will be used. Also note any chemicals which are not on the list. This information should be given to G. N. Boyd; then a meeting can be scheduled for review. B. D. Helms AP00043915 A Cs^fc`&zocduc&- and $&e*ntea&- CALYERT CITY PLANT INTEROFFICE MEMORANDUM To: K. E. Arnold From: B. D. Helms Re: PVC Hygiene Program Date; 1 3 January 1982 Copies: G. N. Boyd, cover only R. C. Lietzau, cover only E. K. McIntyre H. Ortega G. E. Savage R. E. Varllek, cover only During our meeting, 7 January 1982, with Glen Savage and G. N. Boyd, we discussed in some detail the hygiene program. A summary of the discussion follows. - Greg Boyd discussed the overall monitoring program including the data sheets. - A summary of the monitoring data will be available each month. - A respirator use list was presented. - Effective use of monitoring data and the GC system can result in reduction of exposures. Problem, areas are generally in the reactor 3rd floor area. - The leak patrol procedures will be reviewed. - Training with documentation must be conducted per regulation and needs. - Dust exposure in the bagging and bulk loading areas has been a problem. This area will continue to be monitored. - Bagging of copolymer sometimes results in VCM exposures in the warehouse. Fans were installed at the bagger but some product cannot be stored in warehouse. - The Work Practice Standard (15 April 1931) will be reviewed by Arnold and Savage. We will then meet to discuss problem areas. - Emergency procedures must be adopted and training conducted. AP00043916 tachments 1. Hygiene Program Outline 2. 1982 Monitoring Schedule 3. Problem Areas 4. VCH Trend Analyses 5. Resoirator List 5. Data Sheets 7. OSHA Regulationt 3. Work Practice Standard, 15 April 1981 9. Leak Patrol Procedure AP00043917 HYGIENE PROGRAM FOR EACH PLANT AREA I. Identification of A) I Possible Exposures A. Chemicals 1 . Raw rr.a lq rials 2. Products 3. Intermediates 4. By-products B. Noise C. Dust D. Others II. DeteiTiine Basis for Control A. Physical Properties B. Health Effects C. TLV D. Exposure Potential (Evaluation of Work Practice) III. Evaluation of Exposures A. Review Past Monitor Data ys. Control Levels B. Establish Monitor Schedule AP00043918 C. Set Priorities D. Engineering Evaluation - review of Exposure Potent i cl <uic Health Lfft-cts ?`.ay Satisfy Monitoring Requirements. IV. Plan for Uncontrolled Exposures A. Source of Exposure' E. S.W.F. for Explovees Exposed C. Plans for Control of Exposure D. Time Tables E. Schedule for Monitoring Follow-Up If Process or Equipment Changes Are Made V. Change/Shower and Lunchroom Facilities A. Chsnge/Showcr Facilities 1. Do exposures require shower/clothes change? a. Exposure data b. Work practice c. Heal th effects 2. Do facilities meet Group/OSHA standards? 3. Plans B. Lunchroom Facilities 1. Do facilities meet Group/OSHA standards? VI. Reviews (Annually) A. Area Superintendent 1. Approval and commitment to program AP00043919 E. S.HiE. r.rnancr Approval C. Plant Manager Approval AP00043920 HYGIENE PROGRAM TOR EXPOSURE MONITORING I. Schedule A. Scheduling From Each Area Program B. Prioritize From Each Area Program C. Schedule According to A & B and Available Manpower /~3 0. Request to Chemicals Group Hygiene for Analytical Mteiiods If Needed 11. Monitor Method A. Select Method 1. NIOSH-approved, APCI procedure, etc. B. Establish Method Accuracy 1. Calibrate analytical methods, etc. 2. Standards 3. Precision and accuracy data C. Establish Sampling Procedure 1. Select procedure 2. Calibration, before and after sampling D. All Procedures to Methods Book AP00043921 111. r.'C'J-'- nl fit i on -2 A. Analytical Data 1, Document clearly in permanent records {Lab notebook, etc.) . Results 1. Document clearly in permanent records (Lab notebook, etc.) 2. Publish on standard fom 3. Distribute to a. Area superintendent b. S.H.E. manager c. Plant chemist C. Avai 1 abi1ity 1. Data centrally filed in Laboratory 2. Accessible by hygiene chemist, plant chemist, and S.H.E. manager IV. Review A. Results Reviewed With Area Superintendent and S.H.E!. Manager B. Monitor Schedule Re-established Eased on Results 1 AP00043922 RESPIRATOR PROTECTION PROGRAM I. Program Responsibility A. Plant-Wide Coordinator 1. Revision of plant-wide program 2. Audit area compliance to program 3. Assist in training of employee 4. Approve selection of respirators 5. Approve use of respirators B. Area Superintendents 1. Implement program in area 2. Train employees 3. Provide proper respirator equipment 4. Inspect and maintain respirators II. Program Requirements {Minimum) - OSHA 1910.134 A. Standard Operating Procedure (S.W.P.) For Selection and Use of Respirator: 1 . How selected? 2. When used? 3. Basic types of respirators B. Specific Respirators for Hazards Involved 1. Example - VC1 AP00043923 c. Training Program D. Cleaning and Storage E. Inspection Program F. Surveillance G. Physician's Approval For Employee Use H. Approved Respirator List I. Air Systems 1. Airline System 2. Self-contained systems III. Review A. Plant Program 1. Coo rdi nato r;/Safety engineer 2. S.H.E. manager 3. Plant manager B. Area Program 1. Area superintendent 2. Coordinator AP00043924 PVC 1982 Honiioring 5c'nedule Stress or Contaminant ABN Catalyst DMF Drew 1-4 75 ethylene Glycol Ssperox 33M Hydroquinone Luoersol 10M75 Lupersol 11 Luoersol 223M75, ' (or EHP) riethocel E50t F50, K35 Methyl Chloride Methyl Styrene PVC Dust PVP-K-90 Sodium Bicarbonate Sodium Hydroxide Sodium Nitrite Sterox DF Sul furic Acid TCE APCI Limits TWA/STEL - 10 ppm, 20 ppm 10 mg/m5, 20 mg/mPaniculate, Vapor i - - 10 mg/m3, 5 mg/m- Total Rasp 50 ppm, 100 ppm - 10 mg/m3, 5 mg/m2 Tota-1 Resp 10 mg/m3, 5 mg/nr Total Resp 1 0 mg/m3, 5 mg/m3 Total Resp 2 mg/m3 (C) 10 mg/m3, 5 mg/m2 Total Resp - 1 mg/m- 50 ppm, 150 ppn Past Monitorinq Results None 1978, 1979, 1980, <0.5 ppm None None None None None None None None None None \40 samples, 1980, <1 mg/m3 (Area) None None None None None None None Monitor Frequem A A, B A A A A A A A rA\ A A, 6 A, C, H A A A A A A A AP00043925  <n rvc 1982 Monitoring Results Stress or Contaminant Vinyl Acetate APCI Limits TWA/STEL 10 ppm, 20 ppm Vinyl Chloride 1 ppm, 5 ppm Past iIon i tori no Results 1978 (25 samples) <0.5 ppm 1979 (19 samples) <1 ppm ( 1 sample ) 424 ppm 1980 ( 7 samples) <0.5 ppm All past results are computer!zed. i . i -u i' .: Frequency A, C, H A, E, H Noise will be monitored in 1932. Except where noted, all the above sampling results are averages of personnel monitoring. The actual results are tabulated in .the. Industrial Hygiene Sampling Methods book, and each particular test is documented in a-log book" Monitoring Frequency Code: A - Engineering evaluation B - Air sample, every other year C - Air sample, yearly D - Air sample, quarterly E - Air sample, monthly H - Air sampling is high priority for these chemicals. NOTE: 198T monitoring results are reported separately. GNB:07JAN82 AP00043926 1 Problem Areas at the PVC Plant Chemicals with LD50 values less than 500 mg/Kg are considered to be highly toxic. These at the PVC plant are categorized as such: ABN Catalyst DMF Hyriroquinone Sodium Hydroxide Sodi urn Ni tri te Vinyl Chloride (cancer suspect agent) The most likely route of exposure for all the above (except vinyl chloride) is dermal contact rather than inhalation. Therefore, most of the exposures to these chemicals are controlled by the work practice. "Threshold Limit Values (TLY's) are levels to which nearly all workers may be exoosed, day after day, without adverse effect. Short term exposure limits (STEL's) are concentrations to which workers can be exposed from a period up to 15 minutes continuously 'without suffering from 1) irritation, 2) chronic or irreversible tissue change, or 3)narcosis of sufficient degree to increase accident proneness, impair self rescue, or materially reduce work efficiency, provided that no more than four excursions per day are permitted. Threshold Limit Value-Ceiling, (TLV-C) is the concentration that should not be exceeded even instantaneously.1,1 Action levels are H TLV. Chemicals wi th do tenti 3l-- exposures above the action levels are: Vinyl Acetate, TLV 10 oom, STEL 20 opm High exposures to this chemical are generally short-term, limited to jobs such as cleaning filters. PVC Dust, TLV 10 mq/m3 total, 5 mg/m3 respirable Dryer buildings, bagging facilities, and leading areas sometimes generate atmospheres which are very dusty. Even though sampling results indicate average exposures are low, the potential exists for high exposures in these areas. lTLV`s5 ACGIH, 1978. GNB:07JAN82 AP00043927 VCri TREND ANALYSIS TYPE BY MONTH AND YEAR BY EXPOSURE TABLE OF YEARM0 BY EXPOSURE CONTROLLING FUR LOCNAME-CALVERT TWA=8 HOUR THA YEARMO EXPOSURE FREQUEHCYl 0 - .5 1.51 - 1 | ABOVE 1 -r 8106 1 17 1 16 l 1 8107 1 37 1 21 2 TOTAL 34 41 810ft 8109 8110 1 1 I 18 1 20 1 30 I 13 1 21 31 4 4 2 35 26 35 8111 TOTAL 1 18 1 ' HO 0I 36 0 13 18 189 9fl9 FRIDAYt DECEMBER 4, 1981 1 AP00043928 i i